Professional Documents
Culture Documents
DX-10
AM BROADCAST TRANSMITTER
994 9085 002
888-2247-006
I Introduction
II Installation
III Operation
IV Theory of Operation
V Maintenance
VI Troubleshooting/Emergency Procedures
VII Parts List
Subsections
VIII RF
Oscillator
Buffer Amplifier
RF Amplifier Modules
Driver Combiner/Motherboard
Driver Supply Regulator
RF Multimeter
RF Combiners
Output Sample &
Output Monitor
IX Audio
Analog Input
Analog to Digital Converter
Modulation Encoder
DC Regulator
External Interface
X Control
Controller
LED Board
Switch Board/Meter Panel
Test Equipment
888-2247-006 MRH-1/MRH-2
WARNING: Disconnect primary power prior to servicing.
006-G 11-17-03 49774 Replaced Title Page, MRH-1/MRH-2 and Sections 2, 4 and 5.
006-H 04-21-04 50178 Replaced Title Page, MRH-1/MRH-2 and Section H.
006-J 12-10-04 50683 Replaced Title page, MRH-1/MRH-2, section 5 and A.
006-K 04/13/05 51250 Replaced Title Page, MRH-1/MRH-2, and section J.
006-L 03/16/09 53733 Replaced Title Page, MRH-1/MRH-2 and section 2, 4, 5, 6A.
Returns And Exchanges
Damaged or undamaged equipment should not be returned unless written approval and a
Return Authorization is received from HARRIS CORPORATION, Broadcast Systems Divi-
sion. Special shipping instructions and coding will be provided to assure proper handling.
Complete details regarding circumstances and reasons for return are to be included in the
request for return. Custom equipment or special order equipment is not returnable. In those
instances where return or exchange of equipment is at the request of the customer, or
convenience of the customer, a restocking fee will be charged. All returns will be sent
freight prepaid and properly insured by the customer. When communicating with HARRIS
CORPORATION, Broadcast Systems Division, specify the HARRIS Order Number or In-
voice Number.
Unpacking
Carefully unpack the equipment and preform a visual inspection to determine that no appar-
ent damage was incurred during shipment. Retain the shipping materials until it has been
determined that all received equipment is not damaged. Locate and retain all PACKING
CHECK LISTs. Use the PACKING CHECK LIST to help locate and identify any components
or assemblies which are removed for shipping and must be reinstalled. Also remove any
shipping supports, straps, and packing materials prior to initial turn on.
Technical Assistance
HARRIS Technical and Troubleshooting assistance is available from HARRIS Field Service
during normal business hours (8:00 AM - 5:00 PM Central Time). Emergency service is
available 24 hours a day. Telephone 217/222-8200 to contact the Field Service Department
or address correspondence to Field Service Department, HARRIS CORPORATION, Broad-
cast Systems Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. Technical Support
by e-mail: tsupport@harris.com. The HARRIS factory may also be contacted through a FAX
facility (217/221-7096).
Replaceable Parts Service
Replacement parts are available 24 hours a day, seven days a week from the HARRIS
Service Parts Department. Telephone 217/222-8200 to contact the service parts department
or address correspondence to Service Parts Department, HARRIS CORPORATION, Broad-
cast Systems Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. The HARRIS fac-
tory may also be contacted through a FAX facility (217/221-7096).
NOTE
The # symbol used in the parts list means used with (e.g. #C001 = used with C001).
Guide to Using Harris Parts List Information
The Harris Replaceable Parts List Index portrays a tree structure with the major items being leftmost in the index.
The example below shows the Transmitter as the highest item in the tree structure. If you were to look at the bill of
materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the Output Cabinet. In
the Replaceable Parts List Index the Control Cabinet, PA Cabinet, and Output Cabinet show up one indentation level
below the Transmitter and implies that they are used in the Transmitter. The Controller Board is indented one level
below the Control Cabinet so it will show up in the bill of material for the Control Cabinet. The tree structure of this
same index is shown to the right of the table and shows indentation level versus tree structure level.
Example of Replaceable Parts List Index and equivalent tree structure:
The part number of the item is shown to the right of the description as is the page in the manual where the bill for
that part number starts.
Inside the actual tables, four main headings are used:
Table #-#. ITEM NAME - HARRIS PART NUMBER - this line gives the information that corresponds to the
Replaceable Parts List Index entry;
HARRIS P/N column gives the ten digit Harris part number (usually in ascending order);
DESCRIPTION column gives a 25 character or less description of the part number;
REF. SYMBOLS/EXPLANATIONS column 1) gives the reference designators for the item (i.e., C001, R102,
etc.) that corresponds to the number found in the schematics (C001 in a bill of material is equivalent to C1 on the
schematic) or 2) gives added information or further explanation (i.e., “Used for 208V operation only,” or “Used
for HT 10LS only,” etc.).
Inside the individual tables some standard conventions are used:
A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS column means
that this item is used on or with C001 and is not the actual part number for C001.
In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has purchased and
has not manufactured or modified. If the last three numbers are other than 000, the item is either manufactured by
Harris or is purchased from a vendor and modified for use in the Harris product.
The first three digits of the ten digit part number tell which family the part number belongs to - for example, all
electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic (can) capacitor is found
to have a 9xx xxxx xxx part number (a number outside of the normal family of numbers), it has probably been
modified in some manner at the Harris factory and will therefore show up farther down into the individual parts
list (because each table is normally sorted in ascending order). Most Harris made or modified assemblies will
have 9xx xxxx xxx numbers associated with them.
The term “SEE HIGHER LEVEL BILL” in the description column implies that the reference designated part
number will show up in a bill that is higher in the tree structure. This is often the case for components that may
be frequency determinant or voltage determinant and are called out in a higher level bill structure that is more
customer dependent than the bill at a lower level.
2-02-93
WARNING
THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS. PER-
SONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUCTIONS
AND REGULATIONS.
This manual is intended as a general guide for trained and qualified personnel who are aware of the dangers inherent in
handling potentially hazardous electrical/electronic circuits. It is not intended to contain a complete statement of all safety
precautions which should be observed by personnel in using this or other electronic equipment.
The installation, operation, maintenance and service of this equipment involves risks both to personnel and equipment, and
must be performed only by qualified personnel exercising due care. HARRIS CORPORATION shall not be responsible for
injury or damage resulting from improper procedures or from the use of improperly trained or inexperienced personnel
performing such tasks.
During installation and operation of this equipment, local building codes and fire protection standards must be observed.
The following National Fire Protection Association (NFPA) standards are recommended as reference:
- Automatic Fire Detectors, No. 72E
- Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10
- Halogenated Fire Extinguishing Agent Systems, No. 12A
WARNING
ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLO-
SURES, GATES, PANELS OR SHIELDS. ALWAYS USE GROUNDING STICKS AND
SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE IN-
TERNAL ADJUSTMENTS, PERFORM MAINTENANCE OR SERVICE WHEN ALONE
OR WHEN FATIGUED.
Do not remove, short-circuit or tamper with interlock switches on access covers, doors, enclosures, gates, panels or shields.
Keep away from live circuits, know your equipment and don’t take chances.
WARNING
IN CASE OF EMERGENCY ENSURE THAT POWER HAS BEEN DISCONNECTED.
WARNING
IF OIL FILLED OR ELECTROLYTIC CAPACITORS ARE UTILIZED IN YOUR
EQUIPMENT, AND IF A LEAK OR BULGE IS APPARENT ON THE CAPACITOR
CASE WHEN THE UNIT IS OPENED FOR SERVICE OR MAINTENANCE, ALLOW
THE UNIT TO COOL DOWN BEFORE ATTEMPTING TO REMOVE THE DEFEC-
TIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR
WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUB-
SEQUENT INJURY.
i
ii
FIRST-AID
Personnel engaged in the installation, operation, maintenance or servicing of this equipment are urged to become familiar
with first-aid theory and practices. The following information is not intended to be complete first-aid procedures, it is a
brief and is only to be used as a reference. It is the duty of all personnel using the equipment to be prepared to give
adequate Emergency First Aid and thereby prevent avoidable loss of life.
b. Do not break blisters, remove tissue, remove adhered particles of clothing, or apply any salve or ointment.
NOTE
If medical help will not be available within an hour and the victim is
conscious and not vomiting, give him a weak solution of salt and soda:
1 level teaspoonful of salt and 1/2 level teaspoonful of baking soda to
each quart of water (neither hot or cold). Allow victim to sip slowly
about 4 ounces (a half of glass) over a period of 15 minutes. Discon-
tinue fluid if vomiting occurs. (Do not give alcohol.)
b. Do not break blisters, remove tissue, remove adhered particles of clothing, or apply salve or ointment.
AMERICAN RED CROSS STANDARD FIRST AID AND PERSONAL SAFETY MANUAL (SEC-
OND EDITION)
iii
Table of Contents
Section I Frequency Monitor Connection . . . . . . . . . . . . . . . . . . 2-11
Introduction/Specifications Remote Control Connections . . . . . . . . . . . . . . . . . . . . . . 2-11
Scope and Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Functions Which Can Be Controlled Or Monitored . . 2-11
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Interface Information . . . . . . . . . . . . . . . . . . . . . . . 2-11
Remote “CONTROL” . . . . . . . . . . . . . . . . . . . . . . 2-11
Section II
Remote “STATUS” Indications . . . . . . . . . . . . . . 2-12
Installation
Remote Meter Readings (“MONITOR” Out-
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
puts). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Explanation of Selected Functions . . . . . . . . . . . . . . . . . . 2-12
Returns and Exchanges . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
External Interlock (FAIL-SAFE) . . . . . . . . . . . . . . . . . 2-12
Factory Test Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
“OFF” Function (Remote “OFF” Control) . . . . . . . . . . 2-12
General Installation Information. . . . . . . . . . . . . . . . . . . . . . 2-1
PA Turn OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
Transmitter Space Requirements . . . . . . . . . . . . . . . . . . . 2-1
“OFF” Function, “PA Turn OFF,” and External Inter-
Access for External Connections . . . . . . . . . . . . . . . . . . . 2-1
lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Use of OFF, PA Turn OFF, and External Interlock
Transmitter Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Transmitter Grounding & RF Output Connections . . . . . 2-3
Transmitter Turn ON . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Setup Procedures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Raise/Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
General Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
“Forward” and “Reflected” Power, Remote Meter
Equipment Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Pre-Installation Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Bandpass Filter VSWR and Antenna VSWR, Re-
Mechanical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
mote Meter Readings . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Equipment Positioning . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
RF Drive estimate, Remote Meter Reading (at TB1-
Transmitter Leveling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Ground Strap Installation . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Monitor Signal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Electrical Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Remote Status Indications . . . . . . . . . . . . . . . . . . . . . . . 2-13
Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
RF Combiner Crowbar not Operational . . . . . . . . . . . . 2-13
Delta and Wye Connections . . . . . . . . . . . . . . . . . . . . . . . 2-5
Pre-Turn ON Checks; Mechanical . . . . . . . . . . . . . . . . . . 2-13
High Voltage Transformer, Primary winding Termi-
Pre-Turn ON Checks; Electrical . . . . . . . . . . . . . . . . . . . . 2-14
nals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Initial Turn On Procedures . . . . . . . . . . . . . . . . . . . . . . . . 2-14
3 Wire Delta AC Power Wiring . . . . . . . . . . . . . . . . . . . . 2-5
Low Voltage Power Supplies Check . . . . . . . . . . . . . . 2-15
AC Power Wiring, three wire Delta Configuration . . . . . 2-5
Fan Rotation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Transformer connections, 3-WIRE DELTA
RF Driver Operation Check . . . . . . . . . . . . . . . . . . . . . 2-16
CONNECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
PA Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
Blower Motor Junction Box Strapping . . . . . . . . . . . . . . 2-5
Tuning, at about 1 Kilowatt Output . . . . . . . . . . . 2-16
AC Input Power Connection . . . . . . . . . . . . . . . . . . . . . . 2-5
Tuning and Verifying Correct Operation at
4 Wire WYE AC Power Wiring. . . . . . . . . . . . . . . . . . . . 2-7
High Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
AC Power Wiring, Four Wire WYE Configu-
Modulation Monitor;Setting Sample Levels. . . . . . . . . 2-17
ration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Setting Modulation Monitor Sample Level. . . . . . 2-17
Transformer Connections, 3-WIRE WYE
Controller;Battery Backup. . . . . . . . . . . . . . . . . . . . . . . 2-18
Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Installing Batteries . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Blower Motor Junction Box Strapping . . . . . . . . . . . . . . 2-7
Modulation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-18
Other “FOUR WIRE WYE” Connections . . . . . . . . . . . . 2-7
Audio Gain Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . 2-18
AC Input Power Connection . . . . . . . . . . . . . . . . . . . . . . 2-7
Recording Normal Meter Readings . . . . . . . . . . . . . . . 2-18
Power Wiring Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Final Matching Into Antenna . . . . . . . . . . . . . . . . . . . . 2-19
Meter Shunt Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Removing The Shorting Straps On L103 and
Controller Battery Backup . . . . . . . . . . . . . . . . . . . . . . . . 2-9
L104 if required. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Customer Interface Connections. . . . . . . . . . . . . . . . . . . . . . 2-9
Finishing Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Audio Input Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Optional Audio Phasing . . . . . . . . . . . . . . . . . . . . . . . . 2-19
Audio Phasing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Audio Source Impedance . . . . . . . . . . . . . . . . . . . . . . . . . 2-9 Section III
Selecting Source Impedance . . . . . . . . . . . . . . . . . . . 2-9 Operation
RF Output Terminal Installation. . . . . . . . . . . . . . . . . . . . 2-9 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Dummy Antenna Information. . . . . . . . . . . . . . . . . . . . . 2-10 Operating Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
External Interlock (Fail-safe) . . . . . . . . . . . . . . . . . . . . . 2-10 Daily Preoperational Checkout (Local Control). . . . . . . . . 3-1
Using The External Interlock . . . . . . . . . . . . . . . . . 2-10 Daily Preoperational Checkout (Remote Control) . . . . . . . 3-1
PA Turn Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Transmitter Turn-On Procedure . . . . . . . . . . . . . . . . . . . . . 3-1
Modulation Monitor Connection . . . . . . . . . . . . . . . . . . 2-10 Transmitter Turn-OFF Procedure . . . . . . . . . . . . . . . . . . . . 3-2
iv 888-2247-006 03/16/2009
WARNING: Disconnect primary power prior to servicing.
Emergency Operating Procedures. . . . . . . . . . . . . . . . . . . . 3-2 DC Regulator Board, A30 . . . . . . . . . . . . . . . . . . . . 4-9
AC Power Failure (When not using Controller External Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Backup Battery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Digital Terms and Concepts. . . . . . . . . . . . . . . . . . . . . . . . . 4-9
AC Power Failure (When Controller Backup Battery Quantized Amplitude Modulation . . . . . . . . . . . . . . . . . . . 4-10
is used) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Amplitude Modulation - A Review . . . . . . . . . . . . . . . . 4-11
Transmitter Will Not Come ON . . . . . . . . . . . . . . . . . . . 3-2 Amplitude Modulation in the DX-10 Transmitter . . . . 4-11
Transmitter Shuts OFF . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Fault status indications will not clear when reset, or Analog to Digital Conversion . . . . . . . . . . . . . . . . . . . . . . 4-12
Fault Indications Continue to Occur . . . . . . . . . . . . . . 3-3 SAMPLE TIME INTERVAL . . . . . . . . . . . . . . . . . . . . 4-12
Remote Status LED is Red . . . . . . . . . . . . . . . . . . . . . . . 3-3 Digital to Analog Conversion . . . . . . . . . . . . . . . . . . . . . . 4-13
Oscillator, Buffer Amp or Driver Fault . . . . . . . . . . . . . 3-3 DX-10 Power Amplifier Section Principles . . . . . . . . . . . 4-13
RF Amp “Envelope OK” Fault (Remote “Envelope “BIG STEPS” and BINARY STEPS . . . . . . . . . . . . . . 4-14
Error” Fault) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Modulation Encoder . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Audio Input +15V or -15V Fault. A/D Converter RF Output Bandpass Filter. . . . . . . . . . . . . . . . . . . . . . . 4-14
+15V, -15V, +5V Fault . . . . . . . . . . . . . . . . . . . . . . . . . 3-3 Switching RF Amplifiers ON or OFF . . . . . . . . . . . . . . 4-14
A/D Converter Conversion Error Fault. . . . . . . . . . . . . . 3-3 RF Combiner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Modulation Encoder Cable Interlock Fault . . . . . . . . . . 3-3 Summary: DX-10 Digital Modulation. . . . . . . . . . . . . . . . 4-15
DC Regulator +5V or B- Fault . . . . . . . . . . . . . . . . . . . . 3-3 Engineering Description. . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Output Monitor +5V or -5V Fault . . . . . . . . . . . . . . . . . 3-3 Digital Modulation Characteristics . . . . . . . . . . . . . . . . 4-15
Output Monitor VSWR Fault . . . . . . . . . . . . . . . . . . . . . 3-3 AC Power Circuits in the DX-10. . . . . . . . . . . . . . . . . . . . 4-15
Interlocks: External, Air or Door Interlock Fault. . . . . . 3-3 Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Overloads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Overvoltage and Undervoltage Protection. . . . . . . . . . . 4-16
Supply Over Current . . . . . . . . . . . . . . . . . . . . . . . . 3-4 “Brown-Out” Protection. . . . . . . . . . . . . . . . . . . . . . . . . 4-16
VSWR Sensor “Status” Indicator is Red (Remote Phase Loss Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-16
VSWR Self Test Pass/Fail Fault) . . . . . . . . . . . . . . . . . 3-4 Transmitter Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . 4-16
Type 3 Fault Indication (Remote Indication Only) . . . . 3-4 Turning Supplies ON and OFF . . . . . . . . . . . . . . . . . . . 4-16
Bandpass Filter VSWR Fault (Remote: “Internal Low Voltage Supply . . . . . . . . . . . . . . . . . . . . . . . . 4-16
VSWR Fault”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 High Voltage Supply . . . . . . . . . . . . . . . . . . . . . . . 4-16
Antenna VSWR Fault (Remote: “External VSWR Low Voltage Power Supply, Circuit Description . . . . . . . 4-16
Fault”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Low Voltage Supply, Primary Power Circuit . . . . . . . . 4-16
VSWR Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4 Power Distribution Board, A39 . . . . . . . . . . . . . . . . . . . 4-17
VSWR Fault Indication stays ON . . . . . . . . . . . . . . 3-4 High Voltage Power Supply, Circuit Description. . . . . . . 4-17
Tuning and Loading Control Adjustment. . . . . . . . . . . . . . 3-5 High Voltage Supply Transformer T1. . . . . . . . . . . . . . 4-17
High Voltage Supply Primary Power Contactors . . . . . 4-17
Section IV
High Voltage Step-Start (K1, K2, R31-R33) . . . . . . . . 4-17
System Operation
12 Phase Supply and Rectifier Assembly . . . . . . . . . . . 4-17
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Supply Filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Protection of Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Fuses in DC Lines . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Discharging the High Voltage Supply . . . . . . . . . . . . . . 4-1
Power Supply Discharge Circuit . . . . . . . . . . . . . . . . . . 4-18
Location of Door Interlocks and Grounding Switches. . 4-1
Mechanical Shorting Switches, S9 AND S10 . . . . 4-18
Door Interlock Switches . . . . . . . . . . . . . . . . . . . . . 4-2
+115VDC and +230VDC Supply Filter Ca-
Grounding Switches . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
pacitor Discharge Paths . . . . . . . . . . . . . . . . . . . . . 4-18
Non-interlocked compartment . . . . . . . . . . . . . . . . . 4-2
Supply Current Meter, M2. . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Block Diagram Description. . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Fuse Board, A24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
RF Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Voltage Sample Circuits on the Fuse Board . . . . . . . . . 4-19
Oscillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
“Power Supply Protection” Sample . . . . . . . . . . . . 4-19
RF Amplifier Stages . . . . . . . . . . . . . . . . . . . . . . . . 4-8
“Voltmeter” Sample . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Driver Supply Regulator . . . . . . . . . . . . . . . . . . . . . 4-8
High Voltage “Overvoltage” Sample. . . . . . . . . . . 4-19
RF Status Indications: RF Sense Data Lines . . . . . 4-8
“Analog Input” Sample . . . . . . . . . . . . . . . . . . . . . 4-19
Status Indications as Troubleshooting Aids . . . . . . 4-8
Power Supply Sample. . . . . . . . . . . . . . . . . . . . . . . 4-19
Combiner and Splitter . . . . . . . . . . . . . . . . . . . . . . . 4-8
Blower B1, Air Flow Sensing Unit S7 and Tempera-
Power Amplifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
ture Actuated Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Combiners, Output Network and Output Cir-
Blower. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
cuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Air Flow Sensing Unit S7 and Temperature
Audio Input and Modulation Section . . . . . . . . . . . . . . . 4-8
Actuated Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Controller Section (“Controller” and “LED” Boards) . . 4-9
Interlocks and Interlock Relays . . . . . . . . . . . . . . . . . . . . . 4-20
Transmitter Power Supplies . . . . . . . . . . . . . . . . . . . . . . 4-9
Voltage Regulators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20
High Voltage Supply . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Voltage Regulator Assemblies. . . . . . . . . . . . . . . . . . . . 4-20
Low Voltage Supply . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Other Voltage Regulators. . . . . . . . . . . . . . . . . . . . . . . . 4-20
Driver Supply Regulator, A22. . . . . . . . . . . . . . . . . 4-9
03/16/2009 888-2247-006 v
WARNING: Disconnect primary power prior to servicing.
RF Circuit Descriptions, For RF Circuits Not on Offset Adjustment R7 . . . . . . . . . . . . . . . . . . . . . . . 5-4
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 Analog Input Board A35 . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
RF Driver Combiner Description . . . . . . . . . . . . . . . . . . 4-20 Maximum Power Adjust A35R27 . . . . . . . . . . . . . . 5-5
Grounding Block for the Driver and output Com- Modulated B- Adjustments A35R85 (Gain)
biner Secondary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-20 and A35R84 (Offset) . . . . . . . . . . . . . . . . . . . . . . . 5-5
RF Drive Splitter, A15 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Audio Gain Adjust A35R15 . . . . . . . . . . . . . . . . . . 5-5
RF Drive Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-21 Dither Level Adjust A35R43. . . . . . . . . . . . . . . . . . 5-5
RF Power Amplifier Description . . . . . . . . . . . . . . . . . . 4-21 Oscillator A17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
RF Output Combiner Description . . . . . . . . . . . . . . . . . 4-22 Carrier Frequency Adjust A17C1 and A17C3 . . . . 5-6
RF Samples for the Output Combiner . . . . . . . . . . 4-22 Oscillator Sync Adjustment A17S1 and
Bandpass Filter (Output Network) Description . . . . . . . 4-22 A17L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
There are no Operator Tuning Adjustments Driver Supply Regulator A22 . . . . . . . . . . . . . . . . . . . . . 5-6
for the Bandpass Filter/Output Network . . . . . . . . 4-22 Open Loop Adjust A22R2, Closed Loop Ad-
Bandpass Filter/Output Network Circuit Description . . 4-22 just A22R12, Loop Select A22S1 . . . . . . . . . . . . . 5-6
Output Sample/Output Monitor . . . . . . . . . . . . . . . . . . . 4-23 DC Regulator A30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
TEE Matcher: “Tune” and “Load” Controls. . . . . . . . . 4-23 Modulated B- Level A30R38, and Clip Ad-
Adjusting “Tuning” and “Loading” Controls. . . . . 4-23 just A30R39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
To adjust Tuning and Loading:. . . . . . . . . . . . . . . . 4-23 Output Monitor A27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 DETECTOR NULL (Antenna) Adjustment . . . . . . 5-7
Modulation Monitor Sample Coil (L107) . . . . . . . . . . . 4-23 DETECTOR NULL (Bandpass Filter) Adjust-
Spark Gap, E101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23 ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fine Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8
Section V
Trip Threshold Adjustment . . . . . . . . . . . . . . . . . . . 5-8
Maintenance/Alignments
Forward/Reflected Power Adjustments C6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
and C40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Modulation Monitor Sample Adjustments . . . . . . . 5-9
Maintenance Logbook. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
LED Board Replacements A32. . . . . . . . . . . . . . . . . . . . 5-9
Discrepancy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Overload Adjustment Procedures . . . . . . . . . . . . . . . . . . 5-9
Time/Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Under drive Overload A32R92 and Over-
Corrective Action . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
drive Overload A32R88. . . . . . . . . . . . . . . . . . . . . 5-9
Defective Parts(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Average PA Current Overload Set A32R102 . . . . 5-10
System Elapse Time . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Peak PA Current Overload Set A32R98 . . . . . . . . 5-10
Name of Repairman . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Power Supply Protection Overload A32R23 . . . . 5-10
Station Engineer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Envelope Error Fault Indicator A32R65
Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
(Level) and A32R68 (Offset) . . . . . . . . . . . . . . . . 5-10
Maintenance Of Components . . . . . . . . . . . . . . . . . . . . . . 5-1
Board Replacement Instructions . . . . . . . . . . . . . . . . . . . . 5-11
Transistors and Integrated Circuits . . . . . . . . . . . . . . 5-1
Main Combiner/Motherboard Replacement A19 and
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
A20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Fixed Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Replacement of the Main Combiner/Motherboards . . . 5-11
Variable Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Lower Main Combiner/Motherboard Replacement . . . 5-11
Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Binary Combiner/Motherboard Removal and Re-
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
placement A18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Indicators and Front Panel Switches. . . . . . . . . . . . . 5-2
Driver Combiner/Motherboard A14 Removal and Re-
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . 5-2
placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Replacement of the Driver Combiner/Motherboard. . . 5-12
Corrective Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
RF Driver Splitter A15, Removal and Replacement . . 5-12
Replacing Boards and Components on Boards . . . . . . . . 5-2
Blower Motor B1 Replacement . . . . . . . . . . . . . . . . . . 5-13
Boards which can be Replaced with No Adjustments . . . . 5-2
Other Transmitter Circuit Checks . . . . . . . . . . . . . . . . . . . 5-13
Boards which Require Preset Switch Settings or
Airflow Switch S7 Adjustment . . . . . . . . . . . . . . . . . . . 5-13
Jumper Plug Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Tuning/Frequency Change Procedure. . . . . . . . . . . . . . . . 5-13
Modulation Encoder A36 . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test Equipment Required for Frequency Change . . . . 5-13
Controller A38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Installation of Frequency Determined Components . . . 5-14
Buffer Amplifier A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Setting of Frequency Determined Jumpers and
Predriver A10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
RF Amplifiers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
DX10/15 Output Network Tuning . . . . . . . . . . . . . . . . 5-14
Driver Combiner/Motherboard A14 . . . . . . . . . . . . . . . . . 5-4
RF Circuits Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Binary Combiner/Motherboard A18 . . . . . . . . . . . . . . . . 5-4
Oscillator A17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Printed Circuit Boards which Require Adjustments . . . . . . 5-4
Buffer A16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
A to D Converter A34 . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Predriver Adjustment A10 . . . . . . . . . . . . . . . . . . . 5-16
Delay Adjustment R78 . . . . . . . . . . . . . . . . . . . . . . . 5-4
RF Driver Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . 5-17
vi 888-2247-006 03/16/2009
WARNING: Disconnect primary power prior to servicing.
Initial Tuning at Low Power (1 kW) . . . . . . . . . . . . . . 5-18 +5V “B” Circuit Not Up To Operating Volt-
Output Monitor A27 Adjustments . . . . . . . . . . . . . . . . 5-18 age . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
DETECTOR NULL (Antenna) Adjustment . . . . . 5-18 Contactor Turn On Logic . . . . . . . . . . . . . . . . . . . . . 6-1
DETECTOR NULL (Bandpass Filter) Adjust- Contactor Drive Circuitry . . . . . . . . . . . . . . . . . . . . . 6-1
ment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Open Contactor Coil On K1 or K2 . . . . . . . . . . . . . 6-1
Fine Tuning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Symptom: Transmitter Will Not Turn ON-One or
Trip Threshold Adjustment . . . . . . . . . . . . . . . . . . 5-19 More of the Front Panel Indicators is Illuminated
Forward/Reflected Power Adjustments C6 Red. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
and C40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Symptom: Transmitter Will Turn ON but Immedi-
Modulation Monitor Sample Adjustments . . . . . . 5-20 ately Turns OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Final Initial tuning at low Power . . . . . . . . . . . . . . . . . 5-20 Transmitter Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Modulated B-Check . . . . . . . . . . . . . . . . . . . . . . . . 5-20 Symptom: Transmitter Turns ON but there is NO
A to D Phasing Check . . . . . . . . . . . . . . . . . . . . . . 5-21 Power Output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Initial Tuning at High Power (10 kW) . . . . . . . . . . . . . 5-21 PA Turn-Off Command Given To Transmitter . . . . 6-2
Modulated B-Check . . . . . . . . . . . . . . . . . . . . . . . . 5-21 PA Turn-Off Switch Set to the PA OFF Posi-
A to D Phasing Check . . . . . . . . . . . . . . . . . . . . . . 5-21 tion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Final Output Network Tap Settings . . . . . . . . . . . . . . . 5-21 External PA Turn-Off Circuit Activated . . . . . . . . . 6-2
Bandpass Filter Response . . . . . . . . . . . . . . . . . . . 5-22 Transmitter Type 4 and Type 5 Faults. . . . . . . . . . . 6-2
Output Monitor A27 Final Adjustments. . . . . . . . . . . . 5-22 Power Output Of Transmitter Is Lowered To
Antenna and Bandpass Filter Final Adjust- Zero . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
ments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Symptom: Transmitter Turns ON but Transmitter
Forward and Reflected Power Null Adjust- Output is Lower than Normal. . . . . . . . . . . . . . . . . . . . . 6-2
ments A27C3 and A27C4 . . . . . . . . . . . . . . . . . . 5-22 Antenna VSWR Caused By An Impedance
Modulation Monitor Sample Adjustments . . . . . . 5-22 Change In The Transmitter Load . . . . . . . . . . . . . . 6-3
Oscillator Sync Adjustment A17S1 and Bandpass Filter VSWR Caused By Problems
A17L4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 In The Output Network . . . . . . . . . . . . . . . . . . . . . . 6-3
Completion of Basic Frequency Change of DX-10 . . . 5-23 Symptom: Transmitter Turns ON but Transmitter
Binary Amplifier Phase Alignment . . . . . . . . . . . . 5-23 will Not Modulate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Binary Amplitude Alignment . . . . . . . . . . . . . . . . . . . . 5-23 Modulation Not Reaching Transmitter . . . . . . . . . . 6-3
Neutralization Adjustment. . . . . . . . . . . . . . . . . . . . . . . 5-24 Analog Input Board . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Overall Modulated B- Adjustment . . . . . . . . . . . . . . . . 5-24 Troubleshooting Front Panel Indicator Faults. . . . . . . . . . . 6-3
Gain Adjust A35R85 . . . . . . . . . . . . . . . . . . . . . . . 5-24 Overloads- Intermittent or Continuous (indicator
Offset Adjustment A35R84 . . . . . . . . . . . . . . . . . . 5-24 RED or AMBER) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
Modulated B- Level A30R38 DC Regulator Main Power Supply Overcurrent Fault . . . . . . . . . . . . . . 6-3
board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Random Faults With Audio . . . . . . . . . . . . . . . . . . . 6-3
Clip Adjustment A30R39 DC Regulator . . . . . . . 5-24 Faults With Tone Modulation . . . . . . . . . . . . . . . . . 6-4
Other Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Supply Current Overloads on Turn On . . . . . . . . . . 6-5
Audio Gain Adjust A35R15 . . . . . . . . . . . . . . . . . 5-25 Main Power Supply-Overvoltage Fault . . . . . . . . . . . . . . . . 6-5
Offset Adjust A34R75 . . . . . . . . . . . . . . . . . . . . . . 5-25 Supply Voltage Too High. . . . . . . . . . . . . . . . . . . . . 6-5
Dither Adjust A35R43 . . . . . . . . . . . . . . . . . . . . . . 5-25 Main Power Supply-Supply Fault . . . . . . . . . . . . . . . . . . 6-5
Envelope Error Fault Adjusts A32R65 and Input AC 3 Phase Line Imbalance . . . . . . . . . . . . . . 6-5
A32R68 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Open High Voltage Rectifier(s) . . . . . . . . . . . . . . . . 6-5
AM Stereo Installation and Tuning Hints. . . . . . . . . . . . . 5-25 Failed High Voltage Transformer . . . . . . . . . . . . . . 6-5
Interfacing For Stereo . . . . . . . . . . . . . . . . . . . . . . . . . . 5-25 Low Frequency, High Level Modulation. . . . . . . . . 6-6
Adjustments that affect IPM: . . . . . . . . . . . . . . . . . . . . 5-25 RF Driver-Underdrive Fault. . . . . . . . . . . . . . . . . . . . . . . 6-6
RF Driver Tune L2 . . . . . . . . . . . . . . . . . . . . . . . . 5-25 High Voltage Supply Short . . . . . . . . . . . . . . . . . . . 6-6
Bandpass Tuning C101 . . . . . . . . . . . . . . . . . . . . . 5-25 Failed Driver Supply . . . . . . . . . . . . . . . . . . . . . . . . 6-6
No Drive To The Driver Stage. . . . . . . . . . . . . . . . . 6-6
Section VI
RF Driver Module Failure . . . . . . . . . . . . . . . . . . . . 6-6
Troubleshooting
Excessive RF Amplifier Failure . . . . . . . . . . . . . . . . 6-6
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Driver Supply Regulator Failure . . . . . . . . . . . . . . . 6-6
Initial Troubleshooting, Critical OFF-AIR Situations . . . . 6-1
Driver Supply Regulator Loop Select . . . . . . . . . . . 6-6
Symptom: Transmitter will Not Turn On-No Front
Severe Driver Mistuning . . . . . . . . . . . . . . . . . . . . . 6-7
Panel Indicators are Illuminated . . . . . . . . . . . . . . . . . . 6-1
Drive Sensing Circuit Failure. . . . . . . . . . . . . . . . . . 6-7
Loss of AC Power . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
RF Driver-Overdrive Fault. . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Loss of +5V Supply on LED board . . . . . . . . . . . . 6-1
Driver Supply Regulator Failure . . . . . . . . . . . . . . . 6-7
Loose Ribbon or Amp Connectors . . . . . . . . . . . . . 6-1
Driver Supply Regulator Loop Select . . . . . . . . . . . 6-7
Symptom: Transmitter Will Not Turn ON-All Front
Drive Sensing Circuit Failure. . . . . . . . . . . . . . . . . . 6-7
Panel Indicators Are Illuminated Green. . . . . . . . . . . . . 6-1
Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Door Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
03/16/2009 888-2247-006 vii
WARNING: Disconnect primary power prior to servicing.
External Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 Failed RF Amplifier. . . . . . . . . . . . . . . . . . . . . . . . 6-13
External Interlock Terminals Open. . . . . . . . . . . . . . 6-7 Loss Of A Big Step . . . . . . . . . . . . . . . . . . . . . . . . 6-13
External Interlock Fuse F6 . . . . . . . . . . . . . . . . . . . . 6-7 Symptom: Higher than Normal Audio Distortion. . . . . 6-13
External Interlock Relay K4 . . . . . . . . . . . . . . . . . . . 6-8 Failed RF Amplifier(s). . . . . . . . . . . . . . . . . . . . . . 6-13
Air Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Finding a Missing Step . . . . . . . . . . . . . . . . . . . . . 6-13
Blower Not Operating Properly, Failed/Run- Transmitter Mistuning . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
ning Backward . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Operating Into A Bandwidth Restricted Antenna. . . . . 6-15
Top Air Exhaust Restricted. . . . . . . . . . . . . . . . . . . . 6-8 Mistuning Of The Bandpass Tuning Control C101 . . . 6-15
Center Rear Panel Open . . . . . . . . . . . . . . . . . . . . . . 6-8 Low RF Drive Level To The RF Amps . . . . . . . . . . . . 6-15
Air Interlock Sensing Circuitry. . . . . . . . . . . . . . . . . 6-8 Additional Tips For Troubleshooting Audio THD. . . . 6-15
Air Interlock Switch S7. . . . . . . . . . . . . . . . . . . . . . . 6-8 Consistent Loss of RF Amplifier Modules. . . . . . . . . . . . 6-15
All Other Front Panel Faults . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Symptom: Consistent Loss of an RF Amp in one Par-
Oscillator Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 ticular Slot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Buffer Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Improper RF Drive. . . . . . . . . . . . . . . . . . . . . . . . . 6-15
Predriver Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 Improper Drain Phasing. . . . . . . . . . . . . . . . . . . . . 6-15
RF Amp Envelope Error Fault . . . . . . . . . . . . . . . . . . . . . 6-9 Defective Output Toroid . . . . . . . . . . . . . . . . . . . . 6-15
Analog Input +15V and -15V Supply Faults. . . . . . . . . . 6-9 Symptom: Consistent Loss of Modules in Random
A to D Converter +15V, -15V, and +5V Supply Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 A to D Phasing Improperly Set . . . . . . . . . . . . . . . 6-16
A to D Converter Conversion Error Fault . . . . . . . . . . . 6-10 Modulated B- Improperly Set . . . . . . . . . . . . . . . . 6-16
Modulation Encoder Cable Interlock . . . . . . . . . . . . . . . 6-10 Improper VSWR Circuit Operation. . . . . . . . . . . . 6-16
All RF Amplifier Modules Are In Place . . . . . . . . 6-10 Improper Setting Of The Oscillator Sync Cir-
All Modulation Encoder Ribbon cables Are cuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
In Place . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 Improper Overload Settings. . . . . . . . . . . . . . . . . . 6-16
Isolating a Cable Interlock Problem . . . . . . . . . . . . 6-10 Improper Air Flow . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
DC Regulator +5V and B- Supply Faults . . . . . . . . . . . 6-10 Transmitter Mistuning . . . . . . . . . . . . . . . . . . . . . . 6-16
Output Monitor +5V and -5V Supply Faults. . . . . . . . . 6-10 Symptom: Excessive Carrier Shift . . . . . . . . . . . . . . . . 6-16
Output Monitor VSWR Faults . . . . . . . . . . . . . . . . . . . . 6-10 Symptom: Apparent poor Efficiency . . . . . . . . . . . . . . 6-16
Two Stage VSWR Action. . . . . . . . . . . . . . . . . . . . . . . . 6-11 Transmitter Mistuning . . . . . . . . . . . . . . . . . . . . . . 6-16
First Stage VSWR Protection: . . . . . . . . . . . . . . . . . . . . 6-11 Mistuning Of The Bandpass Tuning Control
Symptom: VSWR LED Flashes Red.. . . . . . . . . . . 6-11 C101 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Second Stage VSWR Protection: . . . . . . . . . . . . . . . . . . 6-11 Low RF Drive Level To The RF Amps . . . . . . . . 6-17
Symptom: The VSWR goes to Red and Re- Other Troubleshooting Techniques. . . . . . . . . . . . . . . . . . 6-17
mains on. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Handling MOSFET’s. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Combination of both Stages of the VSWR Circuit Testing MOSFET’s . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Action . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Using FlexPatch™ for Bypassing a Failed RF Amp . . 6-17
Symptom: The VSWR LED flashes then re- Using FlexPatch™ for Isolating Modulation En-
mains lit RED. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 coder/RF Amp Problems . . . . . . . . . . . . . . . . . . . . . . . 6-18
Antenna VSWR Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-11 Measuring RF Drive Level . . . . . . . . . . . . . . . . . . . . . . 6-18
Antenna VSWR Caused By An Impedance Measuring Steps 18-42 . . . . . . . . . . . . . . . . . . . . . 6-20
Change In The Transmitter Load . . . . . . . . . . . . . 6-11 Measuring Binary RF Amp Drive Amplitude . . . 6-20
Bandpass Filter VSWR Fault . . . . . . . . . . . . . . . . . . . . . 6-12 Measuring Drive Phasing . . . . . . . . . . . . . . . . . . . . . . . 6-20
Bandpass Filter VSWR Caused By Problems . . . . 6-12 Scope Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-20
Initial Troubleshooting-less Serious, Not OFF AIR Excessive Drive Phase Difference. . . . . . . . . . . . . 6-21
Situations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 Measuring Steps 18-42 . . . . . . . . . . . . . . . . . . . . . 6-21
Symptom: RF Output and PA Current Lower than Measuring Binary RF Amp Drive Phasing . . . . . . 6-21
Normal-THD may be Higher and RF Amp Enve- RF Amplifier Drain Phasing . . . . . . . . . . . . . . . . . . . . . 6-21
lope Error LED is Red or Flashing Red. . . . . . . . . . . . 6-12 Excessive Drive Phase Difference. . . . . . . . . . . . . 6-22
Failed RF Amplifier Module. . . . . . . . . . . . . . . . . . 6-12 Measuring Steps 18-42 . . . . . . . . . . . . . . . . . . . . . 6-22
Symptom: RF Output and PA Current Lower than
Section VIA
Normal-Antenna and/or Bandpass Filter VSWR In-
Emergency Operating Procedures
dicators are RED . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Intermittent VSWR Condition Causing
What to do if an Overload Occurs . . . . . . . . . . . . . . . . . . . 6-1
Power Foldback . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Power Supply Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Symptom: Loss of Positive Peak Capability . . . . . . . . . 6-12
Crystal Failure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Power Supply Voltage Low . . . . . . . . . . . . . . . . . . 6-12
Predriver Amplifier Failure . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Audio Processor Equipment Defective or In-
High Voltage Power Supply Overcurrent. . . . . . . . . . . . . . 6-2
correctly Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
RF Overdrive or Underdrive . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Incorrect Transmitter Tuning . . . . . . . . . . . . . . . . . 6-12
Transmitter Operated In FlexPatch™ Mode . . . . . 6-13
viii 888-2247-006 03/16/2009
WARNING: Disconnect primary power prior to servicing.
VSWR Protection and Operation under High VSWR Troubleshooting either assembly . . . . . . . . . . . . . . . . . . . . . A-5
Conditions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Symptom: Oscillator LED on ColorStat™ panel is
Emergencvy Operating Procedures for Antenna Red, transmitter will not operate. . . . . . . . . . . . . . . . . . . A-5
VSWR Overload. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2 Possible Cause: Power Supplies. . . . . . . . . . . . . . . . A-5
DX-10 VSWR Protection Circuit Action . . . . . . . . . . . . . . 6-3 Possible Cause: Oscillator Sync Circuit. . . . . . . . . . A-5
Possible Causes of VSWR Overloads . . . . . . . . . . . . . . . . 6-3 Possible Cause: RF Not Present at TP5. . . . . . . . . . A-5
Common causes of Arcing . . . . . . . . . . . . . . . . . . . . . . . 6-3 Symptom: No RF Output, External Oscillator Used. . . . A-6
Load Impedance Changes . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 Possible Cause: RF Input From External Os-
RF Amplifier Failure (Failure of PA Sections) . . . . . . . . . 6-4 cillator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Power Amplifier Description . . . . . . . . . . . . . . . . . . . . . 6-4 Possible Cause: External Input Impedance . . . . . . . A-6
Indications of PA RF Amplifier Failure . . . . . . . . . . . . . 6-4 Possible Cause: Q3 or U5 faulty . . . . . . . . . . . . . . . A-6
Identifying Failed PA RF Amplifiers . . . . . . . . . . . . . . . 6-4 Symptom: Frequency Stability. . . . . . . . . . . . . . . . . . . . . A-6
Substituting for Failed Power Amplifier Sections . . . . . 6-5 Possible Cause: Plug P6. . . . . . . . . . . . . . . . . . . . . . A-6
Possible Cause: Crystal Oven Failure . . . . . . . . . . . A-6
Section VII
Possible Cause: No -15 Vdc Supply . . . . . . . . . . . . A-6
Parts List
Possible Cause: Defective Crystal . . . . . . . . . . . . . . A-6
Section A Symptom: Output At Incorrect Frequency . . . . . . . . . . . A-6
Oscillator (A17) Possible Cause: Frequency Divider Jumper
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Plug P2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Possible Cause: Frequency Divider Fault . . . . . . . . A-6
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Symptom: Oscillator LED on ColorStat™ panel is
RF Flow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Red but transmitter operation is normal. . . . . . . . . . . . . A-6
VSWR Switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Possible Cause: RF Present circuit. . . . . . . . . . . . . . A-6
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Oscillator Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-6
AUTO Switching -004 assembly only . . . . . . . . . . . . . . A-1 Carrier Detect Adjustments . . . . . . . . . . . . . . . . . . . . . . . A-6
Duty Cycle Adjust -004 assembly only . . . . . . . . . . . . . A-1 Oscillator Frequency Fine Adjustment . . . . . . . . . . . . . . A-6
Circuit Description, -002 assembly. . . . . . . . . . . . . . . . . . . A-1 Oscillator Sync Adjustment . . . . . . . . . . . . . . . . . . . . . . . A-6
Supply Voltages and Voltage Regulators . . . . . . . . . . . . A-1 Oscillator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Oscillator Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Buffer/Squaring Amplifier. . . . . . . . . . . . . . . . . . . . . . . . A-1 Additional Installation Steps for HD Radio
Frequency Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 ONLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
External Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2 Final Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-7
Normal or Combined Transmitter Operation . . . . . . . . . A-2
Section B
Frequency Monitor Output . . . . . . . . . . . . . . . . . . . . . . . A-2
Buffer Amplifier (A16)
Oscillator Sync. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Oscillator Output (Buffer-Driver) . . . . . . . . . . . . . . . . . . A-2
Principles of Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
“RF Present” Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Circuit Description, -004 assembly. . . . . . . . . . . . . . . . . . . A-2
Buffer Amplifier Supply Voltage . . . . . . . . . . . . . . . . . . B-1
Oscillator Stage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-2
First RF Amplifier Stage (U1) . . . . . . . . . . . . . . . . . . . . . B-1
Buffer/Squaring Amplifier. . . . . . . . . . . . . . . . . . . . . . . . A-3
Second RF Amplifier Stage (Q1 and Q2) . . . . . . . . . . . . B-1
Frequency Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Third RF Amplifier Stage (Q3 and Q4) . . . . . . . . . . . . . B-1
External Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Output Coupling Network . . . . . . . . . . . . . . . . . . . . . . . . B-1
Internal/External Oscillator and Combined Transmit-
Buffer Amplifier RF Sense . . . . . . . . . . . . . . . . . . . . . . . B-1
ter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-3
Predriver Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
DUTY CYCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
AUTO/MANUAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Symptom: Buffer Amplifier LED on ColorStat™
MUTE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
panel is Red, transmitter will not operate. . . . . . . . . . . . B-1
EXT STATUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Possible Cause: Component failure . . . . . . . . . . . . . B-1
Single Combined Mode . . . . . . . . . . . . . . . . . . . . . . A-4
Possible Cause: Coaxial Cable or Connector
Frequency Monitor Output . . . . . . . . . . . . . . . . . . . . . . . A-4
Fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
VSWR Switching. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Symptom: Buffer Amplifier LED on ColorStat™
Output Buffer/Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
panel is Red, transmitter will operate. . . . . . . . . . . . . . . B-2
RF Present Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-4 Section C
Troubleshooting -004 assembly . . . . . . . . . . . . . . . . . . . . . A-4 RF Amplifier
Oscilloscope Waveform Plots . . . . . . . . . . . . . . . . . . . . . A-4 Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Measure The Power Supplies . . . . . . . . . . . . . . . . . . . . . A-4 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Measure the VSWR-H Input . . . . . . . . . . . . . . . . . . . . . . A-4 RF Amplifier: Basic Theory Of Operation . . . . . . . . . . . C-1
Measure the RF Output . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 RF Amplifier: Half Quad Configuration . . . . . . . . . . . . . C-1
No Signal Present . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-5 RF Amplifier: Full Quad Configuration . . . . . . . . . . . . . C-1
03/16/2009 888-2247-006 ix
WARNING: Disconnect primary power prior to servicing.
RF Amplifier Module On/Off Control Circuit. . . . . . . . C-1 Series Pass Transistors Q5 and Q6 (For Section D1B
RF Transformer Primary Current: Amplifier Off . . . . . C-3 Supply Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Oscillator Sync Signal. . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Voltage Offset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Metering Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Supply Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3 Reference Voltage (CONTROL +VDC) . . . . . . . . . E-3
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 115 Vdc PA Supply Voltage (DRIVER
Cable Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 +VDC). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
RF Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 Driver Current Metering (“DRIVER IDC”) . . . . . . E-3
Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4 Driver Amplifier D1 Voltages (DRIVER 1A
RF Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 +VDC) and (DRIVER 1B +VDC). . . . . . . . . . . . . E-3
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-5 Troubleshooting The Driver Supply Regulator . . . . . . . . . E-3
Symptom: Blown Fuse Indicator Illuminated . . . . . . . . C-5 Symptom: Driver Sect D1A +VDC and Sect D1B
Possible Cause: Shorted MOSFETS. . . . . . . . . . . . C-5 +VDC Both High . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-3
Checking RF Module Operation. . . . . . . . . . . . . . . C-6 Possible Cause: No +15 VDC . . . . . . . . . . . . . . . . . E-3
Possible Cause: Defective U2 . . . . . . . . . . . . . . . . . E-4
Section D
Possible Cause: Defective S1 . . . . . . . . . . . . . . . . . E-4
Driver Combiner/Motherboard (A14)
Symptom: One Output Voltage Is +100 To +110
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Volts, Other Can Be Adjusted. . . . . . . . . . . . . . . . . . . . E-4
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Possible Cause: Shorted MOSFET in a series
RF Driver Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
regulator section (Q3, Q4, Q5 and Q6) . . . . . . . . . E-4
Buffer Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Symptom: Both Driver Supply Regulator Output
Predriver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Voltages Are Zero. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Predriver Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Possible Cause: No +115 Vdc . . . . . . . . . . . . . . . . . E-4
Driver Splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Possible Cause: Driver Supply Regulator
RF Amp/Driver RF Sense. . . . . . . . . . . . . . . . . . . . . . . . D-3
component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
RF Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Symptom: One Driver Supply Output Voltage is
Driver, Section 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Zero, the Other Can Be Adjusted. . . . . . . . . . . . . . . . . . E-4
Driver, Section 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Possible Cause: Shorted Gate-to-Source
Driver, Section 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Zener Diode (CR8, CR11, CR12 and CR14) . . . . E-4
Driver Outputs, Impedance Matching . . . . . . . . . . . . . . D-3
Symptom: Section D1B Voltage Increases Before
RF Driver Combiner . . . . . . . . . . . . . . . . . . . . . . . . D-3
Section D1A Voltage Reaches +100 Volts. . . . . . . . . . E-4
Current Sample Transformer T8 . . . . . . . . . . . . . . . . . . D-3
Possible Causes: Voltage Offset is Too Low . . . . . E-4
Neutralization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-3
Symptom: Open Loop Operation is Correct, Closed
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Loop Operation is Faulty. . . . . . . . . . . . . . . . . . . . . . . . E-4
Connectors and Printed Circuit Board Connectors . . . . D-4
Possible Cause: No RF Sample Voltage . . . . . . . . . E-4
Combiner Toroids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Possible Cause: Shorted Diode in Bridge Rec-
Driver Tuning Components . . . . . . . . . . . . . . . . . . . . . . D-4
tifier CR1-CR4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-4
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Possible Cause: Defective U2 . . . . . . . . . . . . . . . . . E-4
Switch A14S1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Other Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 Section F
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4 RF Multimeter (A23)
Replaceable Parts Service. . . . . . . . . . . . . . . . . . . . . . . . . . D-4 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Section E
Metering Driver Section Parameters. . . . . . . . . . . . . . . . F-1
Driver Supply Regulator (A22)
Multimeter Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Location. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Section G
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 RF Combiners:
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Binary Combiner/Motherboard (A18)
+15 Volt Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 and Main Combiner/Motherboards (A19, A20)
Control +VDC Reference . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
“Open Loop” Reference Voltage . . . . . . . . . . . . . . . E-1 Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
“Closed Loop” Reference Voltage . . . . . . . . . . . . . . E-1 RF Power Combiner . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
RF Drive Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1 Combiner Output Steps . . . . . . . . . . . . . . . . . . . . . . . . . . G-1
Power MOSFET Operation (A Short Review) . . . . . . . . E-1 Main Combiner/Motherboards (A19, A20) . . . . . . . . . . G-2
Regulator Section Circuit Description . . . . . . . . . . . . . . . E-2 DC Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
DC Amplifier Stage (Q2) . . . . . . . . . . . . . . . . . . . . . . . . . E-2 RF Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Series Pass Transistors Q3 and Q4 (For Section D1A Encoded Audio (Module ON/OFF Control
Supply Voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Signals) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
Voltage Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2 Binary Combiner/Motherboard (A18) . . . . . . . . . . . . . . G-2
Binary Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2
x 888-2247-006 03/16/2009
WARNING: Disconnect primary power prior to servicing.
DC Supply Voltages . . . . . . . . . . . . . . . . . . . . . . . . G-2 “Dither” Signal: Function . . . . . . . . . . . . . . . . . . . . . . . . J-4
Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Dither Oscillator (U3, U19, and U5A) . . . . . . . . . . . . . . J-4
Replacing Components . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Oscillator Circuit Description. . . . . . . . . . . . . . . . . . J-4
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-2 Square Wave Generator U19 . . . . . . . . . . . . . . . . . . J-4
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . G-3 Integrator U3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-4
Dither Oscillator Circuit Operation . . . . . . . . . . . . . J-4
Section H
“A/D Big Step Sync” Input to Dither Oscillator. . . . . . . J-5
Output Sample Board (A26) and
-(Audio + DC) Sample to DC Regulator. . . . . . . . . . . . . J-5
Output Monitor (A27)
(Audio + DC) Sample Circuit Description . . . . . . . J-5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Analog Input Board Power Supplies . . . . . . . . . . . . . . . . J-5
Circuit Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
“Dither”: A Description . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
Output Sample Board . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-5
Current Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Printed Circuit Board Maintenance Procedures . . . . . . . J-5
Voltage Samples. . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Replacing CMOS Devices . . . . . . . . . . . . . . . . . . . . . . . . J-5
Output Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-1
Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Phase Angle Detector, Theory Of Operation . . . . . H-1
“Audio Gain Adjust,” R15 . . . . . . . . . . . . . . . . . . . . J-6
Antenna VSWR Phase Angle Detector. . . . . . . . . . H-2
Maximum Power Adjustment (R27, “MAX
Bandpass Filter VSWR Phase Angle Detector . . . . H-2
PWR ADJ”) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
“Phase Angle Detector Null” Meter Indica-
Dither Frequency Adjust, R41 . . . . . . . . . . . . . . . . . J-6
tions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-2
Dither Level Adjust, R43 . . . . . . . . . . . . . . . . . . . . . J-6
VSWR Trip Circuits . . . . . . . . . . . . . . . . . . . . . . . . H-2
“Offset” Adjust, R84 . . . . . . . . . . . . . . . . . . . . . . . . J-6
“VSWR Trip” Logic . . . . . . . . . . . . . . . . . . . . . . . . H-3
“Gain” Adjust, R85. . . . . . . . . . . . . . . . . . . . . . . . . . J-6
AND Gate U5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3
Troubleshooting the Analog Input Board . . . . . . . . . . . . . . J-6
Monostable Multivibrators. . . . . . . . . . . . . . . . . . . . H-3
Symptom. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Directional Coupler Circuit Description . . . . . . . . . H-3
Possible Causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-6
Detected Audio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . H-3
U8, U10, or U11 faulty . . . . . . . . . . . . . . . . . . . . . . J-6
Modulation Monitor Sample . . . . . . . . . . . . . . . . . . H-3
Digital Control Signal at U8 is Zero . . . . . . . . . . . . J-6
+5 VDC And -5 VDC Regulators . . . . . . . . . . . . . . H-4
Power Increases or Decreases in Steps, Not
Section J Continuously . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-7
Analog Input Board (A35)
Section K
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
Analog To Digital Converter (A34)
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
Signal Path Through the Analog Input Board . . . . . . . . . J-1
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
Audio Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
Bessel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
Converting a PA Sample to the A/D ENCODE Pulse
Selecting an Audio Input Connector (J1, J2
(T1, U29, Q9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-1
or J3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-1
Frequency Divider (U29, Q9 ). . . . . . . . . . . . . . . . . . . . . K-1
Balanced Audio Input Stage (U6, U9) . . . . . . . . . . . . . . . J-2
ENCODE Signal Pulse Width (Q9). . . . . . . . . . . . . . . . . K-1
“Instrumentation Amplifier” Operation. . . . . . . . . . . J-2
Analog to Digital Converter Circuit . . . . . . . . . . . . . . . . K-1
Buffer Amplifer (U7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-2
Analog Input Circuit (U28) . . . . . . . . . . . . . . . . . . . K-1
Maximum Power Adjust (U7, R27) . . . . . . . . . . . . . . . . . J-2
Analog to Digital Converter (U1, DL1). . . . . . . . . . K-2
“Power Supply Sample” Circuit (U10, U12B). . . . . . . . . J-2
Digital Data Latches (U3, U4, DL3) . . . . . . . . . . . . K-2
“Analog Divider” U10 . . . . . . . . . . . . . . . . . . . . . . . . J-2
Error Detecting Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . K-2
Power Supply Sample, Circuit Description. . . . . . . . J-2
One-Shot Operation (U13, U14) . . . . . . . . . . . . . . . . . . . K-2
Protection Circuit: R33, R34, CR9, and Asso-
Power Up Reset (C41, R16, U12-F) . . . . . . . . . . . . K-2
ciated Components . . . . . . . . . . . . . . . . . . . . . . . . . . J-3
Clock Error Detection Circuit (U14-A) . . . . . . . . . . K-2
Digitally Controlled Potentiometer (U8) and Output
A/D Converter Monitor Circuit (U13-A). . . . . . . . . K-3
Amplifier (U11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-3
Conversion Error Indicator (U14-B, U11,
BCD Logic Input to Digitally Controlled At-
DS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-3
tenuator U8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-3
Big-Step Sync Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . K-3
Analog Input Board,, BCD Power Control Inputs . . . . . . J-3
Big Step Sync Circuit D/A Converter (U22). . . . . . K-3
Power Control Latches, U17-U18. . . . . . . . . . . . . . . . . . . J-3
Amplifier Stage (U24, U25, U26) . . . . . . . . . . . . . . K-3
“Clock” Input (“Data Strobe” or “Auto
Differentiator and Buffer (U27) . . . . . . . . . . . . . . . . K-3
Strobe” Pulses) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-3
Reconstructed Audio Circuit . . . . . . . . . . . . . . . . . . . . . . K-3
“Reset” Input (Data Clear). . . . . . . . . . . . . . . . . . . . . J-3
Reconstructed Audio Circuit D/A converter
TTL to CMOS Level Shifters (U14, U16) . . . . . . . . J-3
(U8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-3
Analog Buffer Stage (U4A). . . . . . . . . . . . . . . . . . . . J-3
Reconstruction Filter (L1, L2, L3, C47, C48,
PA Turn On/Turn Off Circuit (U13-2, Q1, Q7, U13-
C49) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-3
4, Q2, Q8). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . J-4
Grounds A, AA, B and Chassis . . . . . . . . . . . . . . . . K-3
Differential Amplifier/Inverter U4B . . . . . . . . . . . . . . . . . J-4
03/16/2009 888-2247-006 xi
WARNING: Disconnect primary power prior to servicing.
Voltage Regulators (U2, U16, U18, U19, “INTLK OFF” (“ERROR”) Indication . . . . . . . . . . L-5
U20, U21, Q1) . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 “INTLK ON” Indication . . . . . . . . . . . . . . . . . . . . . L-5
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 “PA Turn Off” Logic. . . . . . . . . . . . . . . . . . . . . . . . . . . . L-5
Printed Circuit board Maintenance. . . . . . . . . . . . . . . . . K-4 Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . L-5
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 PA Turn-Off Indicators . . . . . . . . . . . . . . . . . . . . . . L-7
Sync Sample Phasing (S1) . . . . . . . . . . . . . . . . . . . K-4 Power-Up Reset (U57D, U57B) . . . . . . . . . . . . . . . . . . . L-7
Clock Pulse Width Adjustment (R78) . . . . . . . . . . K-4 Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
Digital to Analog Converter Bit Selection Printed Circuit Board Maintenance. . . . . . . . . . . . . . . . . L-7
(S2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 “CLIP” Patch P15.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
Symptom: ColorStat™ panel CONVERSION ER- Troubleshooting the Modulation Encoder Board . . . . . . . . L-7
ROR Indicator is RED, transmitter operates nor- Symptom: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
mally. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 Troubleshooting Suggestions . . . . . . . . . . . . . . . . . . . . . L-7
Symptom: ColorStat™ panel CONVERSION ER- Symptom: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
ROR indicator is RED, transmitter can be turned Troubleshooting Suggestions . . . . . . . . . . . . . . . . . . . . . L-7
ON. No RF out. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-4 Symptom: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
Check Logic Level at TP8. . . . . . . . . . . . . . . . . . . . K-4 Possible Causes:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-7
CLK ERROR-L: No signal at TP6 . . . . . . . . . . . . . K-4 Additional Troubleshooting Suggestions:. . . . . . . . . . . . L-7
CLK ERROR-L: Signal present at TP6 . . . . . . . . . K-4
Section M
EOC-L FAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-5
DC Regulator (A30)
POWER UP RESET-L FAULT . . . . . . . . . . . . . . . K-5
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
Technical Assistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K-5
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-1
Replaceable Parts Service. . . . . . . . . . . . . . . . . . . . . . . . . . K-5
Circuit Grounds on the DC Regulator Board . . . . . . . . . M-1
Section L UC3834 Integrated Circuit Linear Regulator . . . . . . . . . M-1
Modulation Encoder (A36) OTHER SUPPLIES USING THE UC3834 . . . . . . . . . . M-1
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 Linear Regulator IC Description . . . . . . . . . . . . . . . . . . . M-1
Principles of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 Regulator Circuit Operation . . . . . . . . . . . . . . . . . . . . . . M-2
Modulation Encoding: Explanation and Example . . . . . . L-1 Regulator IC: Fault Logic . . . . . . . . . . . . . . . . . . . . M-2
Modulation Encoding: Read Only Memories . . . . . . . . . L-1 Crowbar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-2
Circuit Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 Regulator IC Thermal Shutdown. . . . . . . . . . . . . . . M-2
SUPPLY VOLTAGES AND POWER SUPPLY IN- +5 Volt Regulated Supply (DC Regulator Board) . . . . . M-2
PUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 Basic Regulator Circuit (U1, Q1) . . . . . . . . . . . . . . M-2
+5 VOLT SUPPLY . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 Turn-On Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3
Modulated B-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-1 Crowbar (Q2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3
Circuit Descriptions: Digital Audio Data Circuits . . . . . . L-1 Other Regulator Circuit Components . . . . . . . . . . . M-3
Data Input Latches (U49, U50) . . . . . . . . . . . . . . . . . . . . L-1 Other Positive Regulated Supplies . . . . . . . . . . . . . . . . . M-3
“Binary Step” Digital Audio Circuits (U31, Modulated B- Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3
U60-U61, U1, U2, U62) . . . . . . . . . . . . . . . . . . . . . L-1 Approximate Modulated B- Supply Output
“Big Step” Digital Audio Circuits PA Module Turn- Voltages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-3
On/Turn-Off Data Circuits . . . . . . . . . . . . . . . . . . . . . . . L-2 Modulated B- Supply: Circuit Description . . . . . . . . . . . M-3
ROM’S (Read Only Memories) AND -(Audio + DC) Input . . . . . . . . . . . . . . . . . . . . . . . . M-3
LATCHES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-2 Modulated B- Supply Regulator Circuit . . . . . . . . . M-4
Patch Plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-2 Other Negative Regulated Supplies . . . . . . . . . . . . . . . . M-4
Inverter/Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-2 Contactor Drivers (U2, Q3, U4 and Q6) . . . . . . . . . . . . M-5
Inverter/Driver Input . . . . . . . . . . . . . . . . . . . . . . . . . L-2 High Voltage Supply Contactors. . . . . . . . . . . . . . . M-5
Inverter/Driver Output. . . . . . . . . . . . . . . . . . . . . . . . L-2 AC Supply for K1, K2. . . . . . . . . . . . . . . . . . . . . . . M-5
Modulated B-. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-2 Contactor Drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5
Data Strobe Signal Circuit: Data Latch “Clock” In- Interlock Status Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . M-5
puts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-3 External Interlock Status . . . . . . . . . . . . . . . . . . . . . M-5
PA Turn-Off (“Data Clear”) Input . . . . . . . . . . . . . . . . . . L-3 Door Interlock Status . . . . . . . . . . . . . . . . . . . . . . . . M-5
“Clip” Function (“Clip-H” and “Clip-L” Signals). . . . . . L-3 Interlock String DC Status. . . . . . . . . . . . . . . . . . . . M-5
“Clip” Function: What Happens if the Clip-L Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5
Patch (P15) is not Connected?. . . . . . . . . . . . . . . . . L-3 Printed Circuit Board Maintenance. . . . . . . . . . . . . . . . . M-5
“Clip” Circuit: Description . . . . . . . . . . . . . . . . . . . . . . . . L-4 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5
Single RF Amp Momentary Test: Pushbutton Switch Regulated Power Supply Troubleshooting . . . . . . . . . . . . . M-5
S2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L-4 Fuse in Unregulated Input Line Open (F1 or F3 on
RF Amplifier Cable Connector Interlock Circuit . . . . . . L-4 DC Regulator Board) . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5
Cable Interlock, Description . . . . . . . . . . . . . . . . . . . L-4 Possible Causes:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . M-5
Cable Interlock Indicators. . . . . . . . . . . . . . . . . . . . . . . . . L-4 Temporary Overvoltage or Transient . . . . . . . . . . . M-5
Table 2-1
Required AC Power Line Service Capacity
Nom. Line Voltage AC Power Disconnect Box Size Nominal Fuse Size Minimum Wire Gauge
Configuration (Notes 1,2) (Note 3)
197V DELTA 100A 70A 4AWG
208V T-1 Configuration 100A 70A 4AWG
219V Ref. 839-6208-241 100A 70A 4AWG
229V 60A 60A 6AWG
240V 60A 60A 6AWG
251V 60A 60A 6AWG
259V 60A 60A 6AWG
270V 60A 50A 6AWG
281V 60A 50A 6AWG
341V WYE 60A 40A 8AWG
360V T-1 Configuration 60A 40A 8AWG
379V Ref. 839-6208-282 60A 40A 8AWG
397V 60A 40A 8AWG
416V 60A 40A 8AWG
435V 60A 40A 8AWG
449V 60A 40A 8AWG
468V 30A 30A 8AWG
Note 1. Blade adapters are commercially available to adapt a fuse to a larger existing disconnect switch.
Note 2. We do not recommend fuses with renewable links.
Note 3. Wire is type THW or equivalent 75 degree C insulation.
2.4 Setup Procedures Bullet for EIA Connector (RF Output Connector)
O-Ring for EIA Connector
2.4.1 General Requirements
Spare RF Amplifier Module - 992-6967-001
Prior to installation, pertinent requirements related to the instal-
lation and operation of the equipment should have been consid- Factory Test Data
ered and provided for. The design considerations should Maintenance Manual - 888-2241-002
encompass physical dimensions of the equipment, access for
C101, Vacuum Variable
Nominal Line Wire Numbers, to T1 Taps: Wire Numbers, to T2 Taps AC to Blower Motor
Voltage AC Input 4,5,6 Jumpers 36 to T2 Tap: 37 to T2 Tap: 60Hz 12,13,106 50Hz 12,13,106
to T1 Taps: 208,209,210 to T1 Taps: to T1 Taps
Jumper between
T1 Taps
197 208 208 to -11 208 -11 +11 -11
208 208 to 0 0
219 208 to +11 +11
229 240 240 to -11 240 -11 -11 208
240 240 to 0 0
251 240 to +11 +11 0
259 270 270 to -11 270 -11 240
270 270 to 0 0
281 270 to +11 +11
Blower Motor Junction Box Strapping, for “Low Voltage”
Nominal voltage required by motor: At 50 Hz: 193 Vac +/-10% At 60 Hz: 230 Vac +/-10%
Junction Box Strapping (Use Wire Nuts for connec- Connect: AC Power Wire #46 to “3" and ”9"
tions): AC Power Wire #47 to “2" and ”8"
AC Power Wire #48 to “1" and ”7"
Connect together: “4", ”5", and “6"
Figure 2-1
Blower Motor Junction Box Strapping for “Low Voltage”
Nominal Line Wire Numbers, to T1 Taps: Wire Numbers, to T2 Taps AC to Blower Motor
Voltage AC Input 4,5,6 Jumpers 36 to T2 Tap: 37 to T2 Tap: 60Hz 12,13,106 50Hz 12,13,106
to T1 Taps: 208,209,210 to T1 Taps: to T1 Taps
Jumper between
T1 Taps
341 208 -11 to -11 208 -11 270 240
360 0 to 0 0
379 +11 to +11 +11 240 208
397 240 -11 to -11 240 -11 270 240
416 0 to 0 0
435 +11 to +11 +11 240 208
449 270 -11 to -11 270 -11 270 240
468 0 to 0 0
Blower Motor Junction Box Strapping, for “Low Voltage”
Nominal voltage required by motor: At 50 Hz: 383 Vac +/-10% At 60 Hz: 460 Vac +/-10%
Junction Box Strapping (Use Wire Nuts for connec- Connect: AC Power Wire #46 to “3"
tions): AC Power Wire #47 to “2"
AC Power Wire #48 to “1"
Connect together: “6" and ”9"
“5" and ”8"
“4" and ”7"
Figure 2-2
Blower Motor Junction Box Strapping for “High Voltage”
In the DX-10, TB3 terminal 4 provides an AC coupled path to 2.7.4 RF Output Terminal Installation
the transmitter cabinet at this point. In some installations, lower Connect the output transmission line from the antenna system to
noise may be obtained by connecting the audio cable shield to the RF OUTPUT 1-5/8" EIA flange connector jack located on
this terminal. top of the transmitter cabinet. Either a male or a female connector
may be used on the coaxial transmission line. If a female con-
a. A CLOSED circuit between TB1-1 and TB1-2 allows the 2.7.7 PA Turn Off
transmitter to turn ON. An External (remote) PA TURN-OFF input turns all PA modules
b. An OPEN circuit between TB1-1 and TB1-2 turns the OFF through modulator section action, causing RF output to go
transmitter OFF by interrupting the 24 volt AC circuit for to zero. The PA is held off as long as the EXTERNAL PA
the high voltage supply contactors. The transmitter cannot TURN-OFF input is present. “External PA Turn-Off” does NOT
be turned on again as long as there is an OPEN circuit turn off the high voltage supply. As soon as the PA Turn-Off
between the External Interlock terminals. signal is removed, the transmitter immediately comes back up to
c. If NO External interlocks are used, a jumper must be its operating power.
connected between External Interlock terminals TB1-1 Don’t confuse “PA Turn Off” with the transmitter “Off” remote
and TB1-2. control input. PA Turn Off operates the same as the “PA
d. The External Interlock circuit is a 24 volt AC circuit, ON/OFF” switch on the controller board. The remote “OFF”
which operates a 24 Vac relay with a 2 volt-amp coil. input operates in the same way as the front panel “OFF” push-
External interlock contacts and wiring should be rated for button switch.
1 ampere AC current.
An External PA Turn-Off input requires applying 15 to 29 volts
between TB1-21 and TB1-23 (observe proper polarity). This
WARNING
input is the same as all other remote control inputs; refer to
DO NOT GROUND ANY PART OF THE EXTERNAL IN- information on Remote Control Connections, later in this sec-
TERLOCK CIRCUIT. The 24 volt AC supply comes from the tion, and to Section N, External Interface, for additional infor-
T1 secondary used for the +30 and +60 volt low voltage supplies; mation on PA Turn Off and other remote control command
the secondary winding center tap is used for both the +30 volt inputs.
output and one side of the 24 volt AC interlock circuit. (See NOTE
Section M, DC Regulator board, for additional information, PA TURN OFF should NOT be used for FAIL-SAFE purposes, or
including a simplified diagram). for interlocks, or for routine transmitter turn off. It is intended to
remove transmitter RF power output during antenna switching
2.7.6.1 Using The External Interlock
operations, for example, during an antenna pattern change.
The External Interlock should be used for any function which
should positively turn the transmitter OFF by turning off its high 2.7.8 Modulation Monitor Connection
voltage supply when an interlock fault occurs. Examples include If a modulation monitor is used at the transmitter site, use a 50
a remote fail-safe connection, and safety interlocks on phasor ohm coaxial cable from BNC jack A27J5 on Output Monitor
cabinets or other enclosures which could expose personnel to the Board A27 to the modulation monitor input. (Output Monitor
transmitter’s RF output when opened. Board A27 is located at the top of the left side wall of the front
NOTE center non-interlocked compartment. See Figure 2-7.) If the
The “External Interlock” should not be used for antenna pattern modulation monitor has a high input impedance rather than an
switching, which requires only brief interruption of RF power
FREQUENCY
DATE
AUDIO MODULATING
FREQUENCY
MODULATION %
CARRIER POWER
PA CURRENT
-8V
+8V
-22V
+22V
RELATIVE RF DRIVE
PA SUPPLY +VDC
RF MULTIMETER
PREDRIVER IDC
PREDRIVER +VDC
REGULATOR +15VDC
DRIVER +VDC
DRIVER IDC
C101
C102
Grounding
Blower
HV Transformer Block
B1
T1 Primary E14
Connections
Figure 2-3
DX-10, Installation Information, Rear View
Figure 2-4
DX-10, Installation Information, Top View
RF Multimeter
A23M1
2 inch round
wiring entance
openings
Low Voltage
Power Supply
Switch S11
Figure 2-5
DX-10, Installation Information, Front View with Doors Open
External Interface
Board A28
RF Multimeter
A23M1
RF Multimeter
Selector Switches
Frequency Monitor
Output J5
Optional External
Oscillator Input
J2
Oscillator
Board
A17
Figure 2-6
DX-10, Installation and Checkout Information, View Showing Right Side of Front Non-interlocked Compartment
Modulation Monitor
Level adjustments
Output Monitor (High and Medium
Board A27 Power)
Modulation Monitor
Sample Output J5
Analog Input
Source Impedance
Shunt, J1, J2, J3
Analog Input
Board A35
Controller
Board A38
Optional
Back-Up
Batteries
"PA OFF"
Switch S5
Figure 2-7
DX-10, Installation and Checkout Information, View Showing Left Side of Front Non-interlocked Compartment
3.7.6 Remote Status LED is Red 3.7.13 Output Monitor +5V or -5V Fault
This is not a fault indication. When the REMOTE status LED is Momentarily push the “Reset” button. If the fault indicator still
illuminated, the transmitter may be operated either by remote remains Red, and will not Reset then that regulator circuit is at
control or from the front panel controls. fault. Check the Troubleshooting section of the manual and the
troubleshooting section for that individual board. The fault must
3.7.7 Oscillator, Buffer Amp or Driver Fault be located and repaired before the fault indication can be cleared.
Fault Indicator is Red or any of the following REMOTE fault
3.7.14 Output Monitor VSWR Fault
indications are present:
Refer to the section on VSWR FAULTS below.
a. Oscillator A17 RF not Present
b. Buffer Amp A16 RF not Present 3.7.15 Interlocks: External, Air or Door Interlock
c. Predriver RF not Present Fault
Do not attempt to operate the transmitter. See the Troubleshoot- Remote fault indications are:
ing section of the manual or the Troubleshooting section of the a. External Interlock Open
particular module at fault. b. Air Interlock Open
c. Door Interlock Open
If the AIR interlock indicator is illuminated Red, depress the
“Reset” button. Again turn on the transmitter by depressing the
Figure 3-1
DX-10 Front View, Controls and Indicators
7 8
10
11 13
12
14
4
15
3
28
30
26 23 22 21
31
25 19 18 16
27 20
29 24
17
Figure 3-3
Status Panel, Controls and Indicators
8
2
1
9
10
11
12
13
Figure 3-4
DX-10 Controls and Indicators, Inside Non-interlocked Compartment and Interlocked Power Supply Compartment
9
10
12
8
6 7
Figure 3-5
DX-10 Controls and Indicators, Left Side of Non-interlocked Compartment and on inside of Front Door
3
2
1
Figure 3-6
DX-10 Controls and Indicators, Right side of Non-interlocked Compartment
The first pages of Section 1 in this Technical Manual describe Rear access panels are secured with quarter-turn fasteners, and
the contents of Sections A through R, or you can refer to the tools are required to remove them. Inside the transmitter, protec-
Table of Contents. This section is organized as follows: tive covers and plastic shields prevent accidental contact with
hazardous voltages, including AC primary power voltages.
a. Protection of Personnel.
Grounding sticks with insulated handles are located inside the
b. Block Diagram Description.
transmitter. Before touching any point which may have had
c. Digital Modulation. voltage applied during operation, make sure all AC power is
1. A short review of digital terms and concepts. removed and use the grounding stick to ensure that no voltage
2. Quantized amplitude modulation. remains.
3. Analog to digital conversion. An External Interlock circuit is available at the external interface
4. Digital to analog conversion. to turn the transmitter off if access doors, panels or covers
5. DX-10 Power Amplifier section: basic principles. protecting personnel from high power RF are removed. The user
6. Summary: DX-10 digital modulator. must provide external interlock switches, as required for each
installation.
d. Circuits not Described in Sections A Through R:
e. Power Supplies and Related Circuits: Most circuit boards in the transmitter operate only from low
voltages, and are located in a non-interlocked compartment.
1. AC Input Circuits: Description.
You can enter this compartment without turning the transmitter
2. Low Voltage Power Supply Description. off by opening the center front door, which is held closed with a
3. High Voltage Power Supply Description. magnetic catch. Within the non-interlocked compartment, no
4. Fuse Board (A24): Description. voltages over 30 volts DC (to ground) or over 70 volts PEAK
5. Blower and Air Flow Sensing Unit. AC are exposed. A plastic shield on the Output Monitor board
6. Interlocks and Interlock Relays. (A27) covers RF sample voltages which could exceed 70 volts
peak.
7. Metering.
f. RF Circuits: 4.2.1 Discharging the High Voltage Supply
1. RF driver combiner description. The Power Supply Discharge board discharges the high voltage
2. RF Drive Splitter A15: Description. supply whenever the transmitter is turned off by the operator, by
3. Power Amplifier Section. a fault, or by an interlock.
4. Output Combiner Description. When the transmitter is turned OFF or when the high voltage
5. RF Samples in the Output Network. supply contactors (K1 and K2) de-energize and turn off the
supply for any other reason (including faults or power failure),
6. Bandpass Filter (Output Network): Description.
contactor auxiliary contacts close and turn on two FETs which
7. Tee Matcher: Description. discharges the high voltage power supplies through low-resis-
8. Modulation Monitor Sample Coil. tance power resistors. (High voltage supplies in the DX-10 are
+230 volt and +115 volt supplies, with high current capability).
Also, when either one of the interlocked access doors is opened,
a mechanical shorting switch directly grounds the high voltage
4.2 Protection of Personnel supply as well.
Interlock switches and power supply grounding have been pro-
4.2.2 Location of Door Interlocks and Grounding
vided on the DX-10 because of the low impedance, high current
capabilities of the high voltage power supply, which can provide Switches
over 75 amperes continuous DC at +230 volts. The front access door on the power supply compartment and the
RF Amplifier module access door at the rear of the front non-in-
There are two safety switches for each of two interlocked doors.
terlocked compartment are protected with interlock switches as
An interlock switch turns the transmitter high voltage supply off
well as the mechanical high voltage grounding switches.
when either door is opened slightly, and when the door is opened
CAUTION
WARNING
DO NOT GROUND ANY CIRCUITS OR POINTS WITHIN THE NON-
TO DE-ENERGIZE THIS TRANSMITTER, TURN THE TRANSMIT- INTERLOCKED COMPARTMENT WHEN AC PRIMARY POWER IS
TER OFF AS YOU NORMALLY WOULD BY DEPRESSING THE APPLIED TO THE TRANSMITTER. USE CAUTION WHEN CON-
OFF BUTTON. THIS WILL DE-ENERGIZE THE HIGH VOLTAGE NECTING ANY TEST LEADS, ESPECIALLY WHEN CONNECTING
SUPPLY. IF YOU MUST ENTER THE TRANSMITTER, SET THE TEST EQUIPMENT GROUND LEADS. ACCIDENTALLY GROUND-
REMOTE/LOCAL SWITCH ON THE STATUS INDICATOR PANEL ING VOLTAGES CAN DAMAGE COMPONENTS OR PRINTED CIR-
TO “LOCAL.” TURN OFF THE WALL DISCONNECT SWITCH TO CUIT BOARD FOIL.
REMOVE ALL PRIMARY POWER. CHECK THE SUPPLY VOLT-
AGE METER TO BE SURE THE HIGH VOLTAGE SUPPLY IS Some circuit grounds and grounding points in the DX-10 are
DISCHARGED. WHEN AN INTERLOCKED DOOR IS OPENED, A carefully controlled, to eliminate ground loops and noise pickup.
MECHANICAL SHORTING SWITCH SHORTS THE HIGH VOLT- Connecting test equipment grounds on some circuit boards may
AGE SUPPLY TO GROUND. GROUNDING STICKS ARE PRO- cause ground loops that result in unwanted noise, reduced equip-
VIDED IN THE TRANSMITTER AND SHOULD BE USED TO AS-
ment performance, or changes in wave forms or voltages. The
SURE THAT ALL VOLTAGE HAS BEEN REMOVED.
Analog to Digital Converter board, A34, is particularly sensitive
Always be sure the voltage is discharged before you open an to improper grounds. Test equipment ground leads should be
interlocked door, otherwise, substantial damage may be done to connected to the proper test point on the printed circuit board
circuit card foil, grounding devices, and the power supply filter when making measurements.
capacitors. Each large power supply filter capacitor has a resistor
directly across its terminals to provide slow discharge in the
unlikely event other discharge mechanisms fail. Also, there are
additional filter capacitors located on the Power Amplifier com- 4.3 Block Diagram Description
biner/motherboards, close to the modules. Each of these capaci- The following brief block diagram description refers to Figure
tors also has a safety bleeder resistor directly across its terminals. 4-1, DX-10 Block Diagram. This description will be most useful
In the power supply compartment, there are some terminals when you are first learning about the DX-10 transmitter.
which have primary AC voltage on them whenever primary Most of the blocks on the block diagram represent printed circuit
power is applied (whenever the wall switch is ON), even if the boards in the DX-10 Transmitter, and if you look at the DX-10
transmitter is turned OFF. These terminals are all protected by Overall Schematic Diagrams, you will find many of the same
covers and protective plastic shields. blocks as printed circuit boards.
WARNING Nearly all printed circuit boards are described in detail in sec-
tions A through R in this technical manual. Some circuits not
PROTECTIVE COVERS INSIDE THE TRANSMITTER SHOULD located on printed circuit boards and a few printed circuit boards
NOT BE REMOVED UNLESS ABSOLUTELY NECESSARY. RE-
with simple circuits are described in the last part of Section 4.
MOVE ALL PRIMARY POWER BEFORE REMOVING ANY PRO-
TECTIVE COVERS. IF PROTECTIVE COVERS ARE REMOVED, 4.3.1 RF Section
REPLACE ALL PROTECTIVE COVERS. ENSURE THAT ALL
COVERS ARE IN PLACE BEFORE CLOSING THE TRANSMITTER The RF Section includes the Oscillator through the Power Am-
DOOR AGAIN. plifier (48 RF Amplifiers), Bandpass Filter, and Tee Matcher.
The RF section generates an RF signal, then several amplifier
stages increase the power to a level high enough to drive the
Power Amplifier stage. The RF amplifier outputs are combined,
Before continuing with a description of DX-10 Transmitter If a longer digital word had been used (more bits in the digital
circuits, the Analog to Digital (A/D) and Digital to Analog (D/A) word), the roundoff or quantization error would be smaller. For
conversion processes will be reviewed. This review will provide example, if the digital word length were 8 bits, it could have any
a background for discussing the transmitter’s modulation sec- of 256 values (from 0000 0000 through 1111 1111). For an
tion. analog signal varying from 0.000 volts through +8.000 volts,
“0000 0000" would now represent voltages from 0.000 through
+0.03125 volts; ”1000 0000" would represent voltages from
4.000 through 4.03125 volts, and so on. By increasing the digital
word length from 5 bits to 8 bits, the maximum roundoff or
4.6 Analog to Digital Conversion quantization error would be reduced from 0.25 volts to 0.3125
The Analog to Digital (A/D) conversion process takes place in
volts.
three steps:
A 12 bit digital word could have any of 4096 values, from
1. Divide the time scale into equal intervals.
0000\0000\0000 through 1111\1111\1111, and would have a still
2. At each time interval, the amplitude (voltage) of the smaller quantization error. As the quantization or roundoff error
analog signal is sampled and recorded. becomes smaller, the series of digital words represents the ana-
3. For each recorded sample, a digital word is constructed log signal more closely.
that represents the analog sample. A key point in Analog to Digital Conversion, then, is:
In the following explanation of these steps, the numbers used do
THE MORE BITS THERE ARE IN THE DIGITAL WORD,
not represent voltages used in the DX-10, but are used only as
THE MORE ACCURATE THE REPRESENTATION OF THE
an example.
ANALOG SIGNAL WILL BE.
a. Divide the time scale into equal intervals.
The RESOLUTION may be expressed as the number of bits in
The analog input signal is a signal which changes with time. (In the digital word. If “n” is the number of bits, the number of steps
the DX-10, this is an audio signal). Each interval or division will represented by a digital word is (2n-1) when the “zero” step is
be a “sample interval.”
not counted. For a 5 bit word, 25-1 = 31 steps; for an 8 bit word,
a. Sample and record the analog signal. 28-1 = 255 steps; and for a 12 bit word 212-1 = 4095 steps.
The analog to digital converter takes a finite amount of time to
4.6.1 SAMPLE TIME INTERVAL
convert the analog signal into a digital word. The input to the
analog to digital converter should not change during the time that The sample time interval used must be short enough so that each
the conversion is taking place. It is necessary to sample the significant change in the analog signal is represented by a new
voltage, then store or record it during the conversion. The signal digital word. A rough “rule of thumb” is that the sample fre-
is sampled at the beginning of the time interval. quency should be at least two times the highest frequency.
Higher sample frequencies will reproduce the analog signal
a. For each sample point, construct a digital word that best more accurately. (The sample time interval, “t” is the inverse of
approximates the analog sample. sample frequency “f” so that t=1/f.)
A digital word is represented by a series of zeros and ones. Each
The sample time interval must also be long enough to allow the
digit in the digital word is called a “BIT.” Each digital word
analog to digital conversion process to take place. The high
represents a range of analog voltages.
speed A/D converter used in the DX-10 requires about 0.9
If a five-bit digital word is used, there are 32 possible words, microseconds (900 nanoseconds) for a conversion.
from “00000" to ”11111." The total analog voltage range, then,
In the DX-10 Transmitter, a 12 bit analog to digital converter
is divided into 32 equal voltage ranges and each digital word
(ADC or A/D converter) is used for high resolution. The effec-
represents one of these voltage ranges. Table 1 shows some
tive resolution of the digital to analog conversion (DAC or D/A
voltage ranges and five-bit digital words for a 0.00 to +8.00 volt
conversion) process in the DX-10’s RF power amplifier stage is
signal. Each digital word represents a range of voltages of
about 11.4 bits, or about 2,800 steps (211.4 is approximately
(8.00/32=0.25) volt.
2800). RF power amplifier resolution is less than 12 bits because
a true binary D/A converter is not used; this will be explained
The High Voltage Supply is located in the Power Supply com- 4.13.4 12 Phase Supply and Rectifier Assembly
partment. The supply transformer, T1, is located on the bottom A 12-phase rectifier assembly provide a DC output with a small
of the compartment. AC contactors are located inside the metal ripple component at 12 times the power line frequency, that is,
cage on the outside wall. Step-start resistors are located at the
CAUTION
5.3 Corrective Maintenance
USE ONLY AN EXACT REPLACEMENT FUSE. FUSES OF THE
SAME SIZE AND/OR RATING FROM A DIFFERENT MANUFAC- 5.3.1 Replacing Boards and Components on Boards
TURER MAY NOT FULFILL THE REQUIREMENT FOR EXACT
REPLACEMENT.
When replacing some boards in the DX-10, preset switch set-
tings or jumper plug positions and some boards require adjust-
a. When a fuse blows, determine the cause before installing ments that must be preset or adjustments and/or measurements
a replacement. that must be made after replacing the board (outlined later in this
b. Inspect fuse caps and mounts for charring and corrosion. chapter).
c. Remove dirt with a small brush.
d. If necessary, tighten fuse clips and connections to the clips.
Fuse clip tension may be increased by pressing the clip
sides closer together. 5.4 Boards which can be Replaced with
5.2.3.6 Switches No Adjustments
Preventive maintenance of switches is accomplished by per- The following boards may be replaced, or components on them
forming the following steps: can be replaced, without making any adjustments, measure-
ments, or preset switch or jumper plug settings:
CAUTION
5.7 Board Replacement Instructions CARE SHOULD BE TAKEN WHEN INSTALLING, REMOVING AND
The following will give specific instructions designed to assist SERVICING THE COMBINER/MOTHERBOARDS. THE LARGE AIR
in the removal and replacement of a few of the boards that require CORE COILS CAN BE DAMAGED DURING HANDLING. ALWAYS
more than just the removal of a few screws. Instructions on CHECK TO MAKE SURE THAT NO TURNS OF THE COILS HAVE
replacing the blower motor are also given. BEEN INADVERTENTLY SHORTED OR THE TAPS ON THE COILS
ARE MOVED SUCH AS TO SHORT TURNS.
5.7.1 Main Combiner/Motherboard Replacement
5.7.2 Replacement of the Main Combiner/Mother-
A19 and A20
boards
The Main Combiner/Motherboards will most likely not require
any service through the life of the transmitter, but if service or Replacement of the Main Combiner/Motherboards is essentially
replacement is required the following procedure can be used. the reverse of the removal procedure. During installation of the
motherboard, it may not appear it fit in as easily as it came out.
WARNING This is due to the blue card guides not fitting back in their slots
at the same time. It is recommended that the board be installed
ENSURE ALL VOLTAGE HAS BEEN REMOVED FROM TRANS- and just a few of the screws be installed that mount the board to
MITTER AND GROUNDING STICK IS USED TO GROUND ALL
the supports. Then from the front of the center compartment,
POINTS WHERE AC OR RF POWER HAS BEEN APPLIED BE-
FORE PROCEEDING WITH THE FOLLOWING PROCEDURE.
place the card guides into their respective slots. Once the moth-
erboard has been fully mounted insert the allen screws that bolt
The two Main Combiner/Motherboards are the center and bot- the Combiner rods together in place but do not fully tighten.
tom boards in the RF compartment. If only removal of the center Loosen the two set screws that are on the fiberglass supports on
board is required, only that board needs to be removed. If the the motherboard that hold the rod in place. Now tighten the Allen
bottom Main Combiner/Motherboard needs to be removed, then screws on the copper rod to 85 inch/lbs. Retighten the set screws
both the middle and the bottom board must be removed. Remove on the motherboard. Replace the Combiner cover, RF Amplifier
the middle Main Combiner/Motherboard as follows. modules, and the interconnection plugs.
Open the front middle door and the front inner door exposing the
5.7.3 Lower Main Combiner/Motherboard Replace-
RF Amplifier modules. Remove RF Amplifiers Step 5 through
Step 12 and Step 29 through Step 36. Even though it is not
ment
necessary, it is recommended that the modules be labeled or kept As noted earlier the middle Combiner/Motherboard must be
in an order such that they can be replaced in their original slots. removed first using the preceding procedure. This same proce-
From where the modules were removed, locate and disconnect dure can be used to assist in removal of the bottom board with
J21 through J26. Also in the front remove the #4 screw that is the addition of the removal of RF Amplifiers Big Steps 13
located in the center partition, at the center of the motherboard. through 28, and a small cover on the top of the bottom Combiner
Look for the long aluminum standoff coming from the center of cover. This will assist in removal and replacement of the two
the PC board. From the rear of the transmitter remove the four allen screws that bolt the bottom of the copper rod. The bottom
drive cable assemblies that attach to the sides of the motherboard Combiner/Motherboard must then slide upward into the area
at J17 through J20. where the middle Combiner/Motherboard was before being able
to pull it straight out.
At this time remove the Combiner cover by removing the #4
screws that attach the cover to all three motherboards, the four
#6 screws that attach the brackets to the top of the cover, the four
#6 screws that attach to the lower Combiner cover, and the four
nents
Using the frequency determined components chart in Section 9,
install all the proper parts listed for the new desired frequency.
There are numerous jumpers that are changed but the only
PARTS that need to change or be checked for proper value are
the following:
Note that the Frequency Determining chart for the output net-
work components also lists the mounting hardware required for
each combination of capacitors. When installing these compo-
nents make sure all connections are tight and use special care
when handling vacuum capacitors.
WARNING
ENSURE ALL VOLTAGE HAS BEEN REMOVED FORM TRANS-
C103 tap
MITTER AND GROUNDING STICK IS USED TO GROUND ALL
POINTS WHERE AC OR RF POWER HAS BEEN APPLIED BE-
FORE PROCEEDING WITH THE FOLLOWING PROCEDURE.
3f trap
5.9.4 DX10/15 Output Network Tuning
1. Dummy load
Connect a suitable 50 ohm non-reactive dummy load to the
output terminal of the transmitter. This can be a small resister,
such as a 1/2 watt to a 2 watt type. Do not use a wire wound
resistor, even if it “non-inductive” and do not use long leads.
2. Third Harmonic Trap Adjustment
Probing the 50 ohm point (input
Disconnect L105 from L103 and L104. Adjust the tap on L105 to the TEE network).
for minimum impedance at the third harmonic of the carrier
frequency. This is a very sharp adjustment, so small adjustments
make a considerable difference. Reconnect L105. See figure
5-1.
3. Tee Network Adjustment
Disconnect the strap from the sand-off below the Output Sample
Board. Connect the impedance meter probe tip to the tubing, and
the probe case to the bracket below the Output Sample toroid.
Adjust the Tuning and Loading controls for 50 ohms, 0 degrees.
Leave the strap disconnected from the standoff below the Output
Sample board for the next step. See figure 5-2.
Figure 5-2
4. Tank Circuit Resonance
Tee Network set up.
Probing C102/C103
Figure 5-5
Z In measuring point.
the case of the impedance meter probe against the shelf. Do not
use clip leads becasue they will alter the impedance measure-
ment. Adjust the C101 tap on L102 and the L101 tap to obtain
3f trap the specified impedance designated as “Z In.” This can be a little
tricky because both adjustments will affect both readings on a
Adjust for the specified Z In vector impedance meter.
8. Restore All Connections
Reconnect the strap to the combiner tubing.
Figure 5-4
Probing C102 9. Check Voltage Clearances
5.9.13 Completion of Basic Frequency Change of Check the drain of Q3 on Big Step 1-3 to verify that they are all
within 2 degrees of each other. Check the drain of Q3 on the
DX-10
Binary Amplifier B-7 (top left module). Note that Q3 is now the
This completes all the basic requirements in changing the fre-
right hand MOSFET when viewing the module from the front.
quency of the DX-10. At this time the transmitter adjustments
Operate the transmitter again at 5 kW. If no wave form appears,
critical to reliability and basic performance have been addressed.
then depress the RAISE or LOWER button until this step turns
The following procedures are given to allow the transmitter to
on. Remember as the power is changed the Binary’s are turning
be checked and adjusted for optimum performance.
on and off at different rates. The vertical sensitivity of the scope
5.9.13.1 Binary Amplifier Phase Alignment can be increased to view the Binary’s since B-7 through B10
The Binary RF Amplifiers B7-B12 are designed to produce operate at 1/2 the supply voltage. If the Phasing of B-7 is within
output RF voltages less that that of the big step amplifiers. This 2 to 3 degrees move to B-8. If it is greater, then the tap on L1 can
is performed by reducing their supply voltage and changing their be changed to put the B-7 amplifier in phase. Note that typically
output transformer turns ratio. This causes the Binary amplifiers more of the inductor will be shorted out for the Binary’s than for
to not always operate at the same output phase of RF as the Big the Big Steps. Do not reduce Efficiency coil turns to less than
Steps. This phase difference can be anywhere from 0 to 30 1/2 of the given Frequency determined value.
degrees. Because the Binary’s operate at lower powers this
Continue to check the phasing on the remaining binary’s. Note
situation does not affect reliability but can have an effect on the
that the amount of active turns on the Efficiency coils will tend
amount of IPM products the transmitter produces. Therefore
to be less on the smaller binary steps. B-11 and B-12 only operate
mainly this Binary Amplifier Phase alignment is performed to
on a 30VDC supply and therefore will not be able to phase align
achieve optimum stereo performance. This alignment is per-
to 0 degrees as the other binary’s would. For B-11 and B-12 set
formed by measuring the phase difference between the Big Step
the coil taps for 1/2 of the normal FD value on the Big Steps and
Amplifiers and the Binary’s at the output of each amplifier and
accept the amount of drive phase error (typically 5 to 15 degrees).
adjusting the tap on the Efficiency coil for that amplifier to
This error is not critical since these two steps operate at 1/32 and
within 2 degrees of the big steps.
1/64th of the amplitude of a big step.
WARNING 5.9.14 Binary Amplitude Alignment
ENSURE ALL POWER IS REMOVED FROM TRANSMITTER AND The output of the Binary Amplifiers can very from frequency to
THAT GROUNDING STICK HAS BEEN USED TO DISCHARGE frequency. To optimize the linearity of the modulation signal,
ANY RESIDUAL POTENTIAL WHERE POWER HAS BEEN AP- the output amplitude of the Binary amplifiers can be varied in
PLIED ANY TIME THE INNER FRONT DOOR IS OPENED TO 5% increments. To check the Binary alignment, operate the
ACCESS THE RF AMPLIFIER MODULES.
transmitter at 1 kW output with 100Hz triangle modulation.
Normally the taps on the Efficiency coils for the Binary amps Triangle or ramp modulation must be used for this procedure.
should already be preset to some value per the frequency tuning On the scope display the demodulated output of the modulation
chart. Open the inner front door of the transmitter and connect a monitor. Use the external sync on the scope connected to the
X10 scope probe to the drain of Q3 on the Step 1 RF amp. The output of the generator. Expand the vertical and horizontal
drain is the center pin of Q3 which is the left hand MOSFET display to view the positive going portion of the ramp. Connect
front the heat sink. Route the X10 probe and cable on the scope the other channel of the scope to the Modulation Encoder gold
such that the inner front door can be closed. NOTE: A X10 jumper for Step 5. Raise or lower the modulation until a transi-
SCOPE PROBE MUST BE USED. ALSO ENSURE THAT tion from 0V to 5V can be seen on the Step 5 display. From this
THE SCOPE CASE IS PROPERLY GROUNDED. Set the display it is possible to see at which point in the modulation ramp
scope on AC coupled, 50V per division with trace centered on Step 5 is being turned on. Now look at the Modulation Encoder
the screen. Connect the external sync of the scope to J5 on the signal for Step 6. Raise and lower the modulation until it can be
oscillator board and make sure the scope sync is set to External. seen turning on. It may also be noted where a big step turns on
Operate the transmitter at 5 kW with no modulation. Adjust the by a small glitch that may appear in the demodulated wave form.
Horizontal vernier on the scope so that one full RF cycle occu- See Figure 5-17. By both making small changes in power level
pies 9 divisions on the screen. Each division now equals 40 and modulation level it should be possible to display the de-
degrees of phase shift. Using the Horizontal positioning and modulated ramp between two big steps. This is the area to look
triggering level on the scope place the transition time of the scope at for binary alignment. If the binary alignment is proper, the
on the center vertical line of the screen. Increase the vertical transitions between big steps will be smooth. If, for instance, the
sensitivity of the scope to expand the wave form. Switch the 1/2 Step B-7 amplitude was too low you will see a glitch halfway
scope to the X10 position and readjust the horizontal position so between Step 5 and Step 6. This is the half step transition. You
that the RF transition again crosses the center line of the scope. may also see that there is now a glitch at Step 5 and Step 6 also.
This will be the reference for the phase measurements. If another See Figure 5-18.
Figure 5-9
Driver Transformer tap setting diagram
A14T7, T10 and T11.
Figure 5-11
RF Drive wave form at RF Amplifier, Gate of Q3 (Anode of CR7).
RF Amplifier turned “ON”. (5 Vp-p per division)
Figure 5-14
Modulated B- wave form at DC Regulator A30TP7. 10kw operation with 100 Hz,
100% modulation. 1 V per division, 0.0 VDC at top line.
Figure 5-16
Oscillator sync samples at Oscillator A17TP4 and TP5. Transmitter operating at
10kw with no modulation. The two samples are in phase. (1 V per division)
Figure 5-18
Demodulated audio. Transmitter operating at 1kw with 100Hz, approximately 10% triangle modulation.
Top trace-Demodulated audio.
Bottom trace-Modulation Encoder wave form of Step 6.
Insufficient 1/2 Binary Step output shown.
Steady State RED Lower than Normal at all powers RF Amp Failure Check LEDs on RF Amp
Modules from Step 1-18*
Flashing RED with Modulation OK @ 1kW, LOW RF Amp Failure, Check LEDs on RF
@ 1-kW AMP Modules from Step 6-18* Flashing
RED with Modulation OK @ all Power RF Amp Failure, Check LEDs on RF Amp
Levels Modules from Step 18-42*
Flashing RED with Modulation OK @ all Power If NO RF Amp LEDs are lit, suspect load
Levels change, check tuning. Also, decreased an-
tenna bandwidth will cause the LED to
flash with high level, high frequency
modulation.
Figure 6-2
Upper trace-Demodulated audio for transmitter operating at 10kw, 125%+peak,
triangle modulation. Showing missing step 39.
Lower trace-Modulation Encoder signal for missing step 39.
Figure 6-5
RF drive waveform as seen at RF amplifier, Gate of Q3 (anode of CR7).
RF amplifier turned ON (5V p-p per division).
Figure 6-7
RF drain waveform as seen at RF amplifier drain of Q3, RF amplifier turned ON.
Showing zero crossing of reference phase and measured phase
approximately 2 degrees lagging. 1V p-p per division, X10 MAG.
a. The red status indications should be logged or recorded. The Driver Supply Regulator utilizes a two stage linear regula-
tor. During normal operation, only the first stage of the Driver
b. Push and release the RESET button on the status indicator
Supply Regulator is turned on. It is possible for that section to
panel. When the RESET button is released, all status
fail and the second section will take over. A dramatic change in
indicators will remain green unless a fault is still present.
the DRIVER SECT. 1A and DRIVER SECT 1B. readings will
If one or more status indicators are still red, either the fault
be noted but no other change in the transmitter operation will
must be corrected or, in some cases, appropriate emer-
occur. If this condition is noted the Driver Supply Regulator
gency action may be taken to continue operation if desired.
should be serviced as soon as possible. The transmitter will
Refer to Section VI of this Technical Manual for assis-
operate in this Emergency position until then. DO NOT attempt
tance.
to adjust the Driver tuning control L2, during a Driver Supply
c. If all Status indicators remain green after the RESET Regulator fault.
button is released, depress the LOW, MEDIUM, or HIGH
pushbutton switch on the transmitter to turn the transmitter
back on.
d. If no further fault occurs, meter readings should be 6.4 Crystal Failure
checked for possible abnormal readings.
Crystal failures include complete failure to oscillate, low crystal
e. If a Power Supply Overcurrent overload, or a VSWR fault output, or oscillation off frequency. In case of crystal failure,
(both indicated by the Status Indicator turning RED) oc- operation can be continued by using the other crystal. To accom-
curs again, try operating the transmitter at reduced power. plish this, use the following procedure:
Further information is given in paragraphs “High Voltage
a. Change crystals by moving the jumper in plug P1 on the
Power Supply Overcurrent and VSWR Protection” and
Oscillator board to the other position. (If the P1 jumper is
CAUTION
6.6 High Voltage Power Supply Overcur- VSWR overload limit settings that exceed recommended values may result
in component damage or failure.
rent
If supply overcurrent faults occur with high level modulation,
and supply current is not excessive, then reducing modulation
level and/or reducing transmitter power output may permit con-
tinued operation until the transmitter can be shut down to locate 6.9 Emergencvy Operating Procedures
and correct the problem. for Antenna VSWR Overload
If the ANT VSWR status indicator stays RED, and the DX-10
has reduced its power output, but the antenna system is still
radiating a signal and the reflected power meter indicates some
6.7 RF Overdrive or Underdrive power level, then something has caused an impedance change in
If the problem is a Predriver problem, refer to the “Predriver the transmitter load. Emergency Action that may be taken to
Failure” paragraph above. If the problem is due to an Underdrive continue operation includes the following steps:
Overload, note if any of the Driver module faults LED’s illumi- a. If possible, reduce the reflected power meter reading with
nate as soon as the high voltage is applied. If this does occur, the TUNING and LOADING controls. If the load imped-
then replace that Driver module. If no module fault indicators ance change is not too great, it will be possible to compen-
illuminate, the problem may be due to a Driver Supply Regulator sate for it with these two controls.
problem. Locate the three access holes above the Oscillator b. Depress the Reset button on the front panel to extinguish
board which allow access to the Driver Supply Regulator Ad- the VSWR fault indicator(s). If reflected power can be
justments. With an insulated tool set the LOOP Select switch reduced with the tuning and loading controls, the transmit-
A22S1 to the OPEN LOOP position. If the transmitter now ter output power may be increased until the VSWR lamp
operates, there is a problem with the Closed Loop regulator
Table 7-28 PWA, OSCILLATOR (alternative to 992 8069 002) . . . . . 992 8069 004 7-35
Table 7-4. XMTR, BASIC, DX-10 10KW - 994 9085 002 (DH)
Harris PN Description QTY UM Reference Designators
007 4060 060 BRZ, FGR STK OC97-438-04 1.0 FT
026 6010 003 GROMMET STRIP, 0.125 4 ME
0311810015A *GSKT, .125 X .500 10.0 FT
0416030010A *RUBBER CHANNEL X650 1.0 FT
2960344000A *TUBG, POLYETHYLENE 1/4 OD 6 FT
296 0348 000 TUBG,POLYETHYLENE 3/8 OD 0 FT
302 0551 000 SCR, SOC HD SHOULDER 2.0 EA #FRT DOOR
304 0039 000 NUT CAP .312-18 BRS 2.0 EA #E101
304 0166 000 NUT, SQ. BRASS, 1/4-20 2.0 EA #L105
354 0894 000 LUG, ADAPTER, SPADE, 0.187 4 EA #C008,#C009
356 0094 000 ADHESIVE CABLE CLIP 1.0 EA
356 0110 000 CABLE CLAMP 3/4 D 1 EA RF DRIVE CABLE CLAMPS
357 0067 000 NUT, ACORN CAP 10-32 6.0 EA #M001,#M002,#M003
358 0003 000 BRACKET RESISTOR MTG 8.0 EA #R008,#R009,#R010,#R011
358 0437 000 BUSHING PANEL .252 ID 2.0 EA #L001,#L002
358 0498 000 CLAMP, HOSE 12.0 EA
358 0960 000 CPLR, 1/4"X1/4" SHAFT 2.0 EA #L001,#L002
358 2426 000 PLUG, WHITE 2" HOLE 4.0 EA
358 2511 000 STANDOFF, 10-32 X 3/4 2.0 EA #S009
358 2588 000 FLAT CABLE MOUNT 1.0 EA
358 2589 000 FLAT CABLE MOUNT 10.0 EA
358 2598 000 CABLE TIE MOUNT, 4-WAY 3.0 EA
358 2635 000 CABLE TIE, PUSH MOUNT SNAP IN 30.0 EA
358 3109 000 STUD, BRS 8-32 X 1 4.0 EA 2#T101 2#T102
358 3121 000 STUD, BRS 10-32 X 1 2.0 EA #C037,#XF006
358 3123 000 STUD, BRS 10-32 X 1-1/2 9.0 EA #C003,E007,E008,E009,E010,E011,E012,E013,
E048
358 3134 000 STUD, BRS 1/4-20 X 1-3/4 12.0 EA #CR1-12,#E015,#L107 2#A26 2#E014
358 3300 000 FLAT CABLE MOUNT - BASE 3 EA # USE WITH COVER 358-3301-000
358 3301 000 FLAT CABLE MOUNT - COVER 3 EA # USE WITH COVER 358-3300-000
358 3660 000 ALLEN, 5/32 HEX, CUSHION GRIP 1.0 EA #TOOL FOR LATCHES
359 1199 000 ADAPTER 1/4OD COMP X 1/8 MIP 1.0 EA
384 0702 000 RECT FW BRIDGE 600V 35A ESD 4.0 EA CR013,CR014,CR015,CR016
384 0839 000 RECT 1000PIV 275A 1N4056 ESD 6.0 EA CR001,CR003,CR005,CR007,CR009,CR011
384 0840 000 RECT 1000PIV 275A 1N4056R ESD 6.0 EA CR002,CR004,CR006,CR008,CR010,CR012
398 0433 000 FUSE 1 TIME 6A 250VAC 1.0 EA A24F1
398 0440 000 FUSE 1 TIME 15A 250VAC 5.0 EA A24F3,A24F8,F001,F002,F003
398 0441 000 FUSE, ONE-TIME, 25A 250V 5.0 EA A24F2,A24F4,A24F5,A24F6,A24F7
398 0442 000 FUSE 1 TIME 1A 250VAC 1.0 EA F006
398 0470 000 FUSE TIME DELAY 3A 250VAC 3.0 EA F007,F008,F009
402 0001 000 CLIP, FUSE 1.062 60A 600V 2.0 EA #R038
402 0015 000 FUSE HOLDER, 3 POLE 3.0 EA XF1-3,XF4-6,XF7-9
402 0107 000 CLIP, FUSE 9/16 6.0 EA 2(#358-3660)
Table 7-17. PWA, SPLITTER, RF, ESD SAFE - 992 6958 001
Harris PN Description QTY UM Reference Designators (E)
414 0310 000 TOROID, FERRITE 1.0 EA
610 0998 000 HDR, 6 PIN, PC BD 1.0 EA J013
610 1072 000 HEADER 20 POS RIGHT ANGLE 12.0 EA J001 J002 J003 J004 J005 J006 J007 J008
J009 J010 J011 J012
817 1280 041 HAIR PIN, RF SPLITTER 24.0 EA
843 4038 097 PWB, RF SPLITTER 1.0 EA
Each crystal is contained in a sleeve type oven, which maintains either 50 ohms or approximately 20k ohms, depending on the
temperature at 70°C (+/-3°C, approximately). Oven jumper plug position of jumper plug P5. The high impedance input is for use
P6 supplies -15Vdc to either oven. Note that crystal jumper plug with TTL level (4 to 4.5 volt peak-to-peak square wave). With a
P1 and oven jumper plug P6 must both be in the same position, 50 ohm input impedance, RF input levels from 0 to +25 dBm can
otherwise the crystal in use will not be at the correct temperature be accommodated. (At 50 ohms, 0 to +25 dBm is 1 mW to 316
and may be off frequency (P1 and P6 must both be in the upper mW, or 0.22 V rms to 4 V rms).
position, or both in the lower position). Amplifier Q3 and buffer/driver U5B provide a logic-level signal
A.5.2 Buffer/Squaring Amplifier to Test Point 8. Diodes CR8 and CR9 at Q3 input provide
protection against excessive input voltages.
Buffer amplifier Q2 is coupled to the oscillator output, and
operates as an overdriven amplifier, with a +5 volt supply A.5.5 Internal/External Oscillator and Combined
voltage. The output of Q2 is a TTL-level square wave which Transmitter Operation
drives the frequency divider. Diodes CR2 and CR3 protect Q2
Jumper plugs JP4, JP5, JP6 are used to select either the internal
against reverse voltages.
oscillator, an external oscillator or Automatic. The signals at this
A.5.3 Frequency Divider point are 4 to 4.5 volt peak-to-peak square wave signals (logic
Integrated circuits U1 and U2 are dual J-K flip-flops, used as level signals) at the transmitter’s operating frequency. JP4 se-
frequency dividers. Each IC section is connected as a divide-by- lects the internal crystal oscillator, JP5 selects the external oscil-
two circuit. The signal at U2-11 and P2-2, is one-fourth of the lator source and JP6 puts the board in Automatic mode.
crystal frequency. Half of U1 divides this frequency by two, so JP1 is used to invert the signal, used only in combine mode when
the signal at U1-15 output, and P2-3, is at 1/8 of the crystal needed.
frequency. Jumper plug P2 is then installed to route either the When JP6 is installed then the Oscillator Board is in the AUTO
divide-by-four or the divide-by-eight output to buffer-driver Mode. When an Ext Rf Signal is applied at J2 and a signal is
U5A, pin 2. The output of U5A-7, at Test Point 14, is a TTL-level present at TP8 this causes a retriggerable monostable vibrator to
square wave at the transmitter operating frequency. have a Logic “1” on the Q output. This output turns “ON” Q10
A.5.4 External Input which then applies a Logic Low to the U10 Pin 2 when P8 is in
Position 1-2. When U10 is enabled this provides a low to U9 pin
An HD Radio Exciter, AM stereo generator or high-stability
10 and 13. Pin 8 of U9 will be low and Enable DS1 And the
external oscillator can be connected to BNC jack J2, which is
CMOS switch (U8) which switches to the External RF signal.
located on the Oscillator board. The external input impedance is
A.7.3.2 Possible Cause: Crystal Oven Failure This adjustment is used to detect the loss of the External RF
The crystal oven which is operating should be hot. signal. When RF is lost for 5-8 cycles U7 will be set causing the
“Q” output to go low. This in turn causes the CMOS switch to
A.7.3.3 Possible Cause: No -15 Vdc Supply
switch to the Internal Crystal.
Check for -15 Vdc at P6-1. If not present, check both ends of F2
for -22 Vdc. If F2 is open, replace it. If the fuse opens again, U6 A.8.2 Oscillator Frequency Fine Adjustment
is probably defective. a. Connect a frequency counter or frequency monitor to the
A.7.3.4 Possible Cause: Defective Crystal Oscillator to the Oscillator board Frequency Monitor Out-
Defective crystals may operate off frequency. If one crystal can put (BNC Jack J5).
be adjusted to the correct frequency but the other cannot, the b. Select the crystal to be adjusted, make sure its oven is
off-frequency crystal is probably defective. operating and warmed up.
A.7.4 Symptom: Output At Incorrect Frequency c. Adjust C1 (for crystal Y1) or C3 (for crystal Y2) for the
desired frequency. Only a small range of adjustment of
A.7.4.1 Possible Cause: Frequency Divider Jumper Plug P2 frequency is possible.
Check the position of the P2. The crystal frequency will be
divided by four if P2 is from 1-2, and will be divided by eight if NOTE:
Crystal jumper plug P1 and Oven jumper J6 must both be in the
P2 is from 1-3. Check your crystal frequency and the jumper same position during adjustment or operation. Do not adjust fre-
position. quency for either crystal until its oven has had sufficient time to
A.7.4.2 Possible Cause: Frequency Divider Fault warm up, allowing at least 15 minutes.
Normally a frequency divider fault will result in complete loss A.8.3 Oscillator Sync Adjustment
of rf at P2-1. The output of a frequency divider section will go
Using a dual trace scope:
to either 0 Vdc or to +5 Vdc. Using an oscilloscope, check the
oscillator frequency at Q2 collector, and divider frequencies at a. Connect channel 1 to TP5.
P2. Frequency at P2-2 should be 1/4 the oscillator frequency and b. Connect channel 2 to TP4.
at P2-3, should be 1/8 the oscillator frequency. c. Sync the scope to channel 1.
A.7.5 Symptom: Oscillator LED on ColorStat™ panel d. Set the sweep speed on the scope to display one or two
cycles of RF.
is Red but transmitter operation is normal.
e. Operate the transmitter at maximum TPO, and note that at
A.7.5.1 Possible Cause: RF Present circuit
this time, channel 2 will also have a 5Vp-p squarewave
CR6 and CR7 “RF Present Detectors.” Check for +4 to +5 Vdc
displayed.
at CR7 cathode and for -4 to -5 Vdc at CR6 anode. If a normal
rf level is present at the Oscillator board output but one or both
Table A-1
Carrier loss Detection R64 adjustment.
Freq 500 540 640 740 840 940 1040 1140 1240 1340 1440 1540 1640 1740
(kHz)
Ohms 23 21 17 14 11 9 8 7 6 5 4 4 3 3
(k)
Oscillator Board
Jumper # Jumper Position Description
Pins 1-2 Pins 1-3
P1 Activates Crystal Y1 Activates Crystal Y2
P2 For 1251kHz & Above, selects divide by 4 For 1250kHz and below, selects divide by 8
P4 Can be used for Combined Transmitter Operation Selects Normal Single Transmitter Operation
P5 Sets Input Impedance for External Oscillator. Sets input Z for External Oscillator Input at 50
Input at 20k Ohms for TTL Levels Ohms for 0-25dBm Input
P6 Activates Oven for Crystal Y1 Activates Oven for Crystal Y2
P7 +5V External Failsafe Disabled +5V External Failsafe Enabled
P8 External Carrier Detect ON External Carrier Detect OFF
JP4 (see note at right) Selects External Oscillator Inputs from J2
JP5 (see note at right) Selects Internal Crystal NOTE: ONLY one of these three jumpers can be
installed at a time
JP6 (see note at right) Uses CMOS switch of RF Signals
J3-1
-004 assembly
Figure C-2
RF Amplifier operation, half quad configuration.
Figure C-3
RF Amplifier operation, full quad configuration.
Figure H-1
Phase Angle Detector simplified diagram.
The modulation encoder board is located in the non-interlocked L.3.1 SUPPLY VOLTAGES AND POWER SUP-
compartment, on the left side. PLY INPUTS
Refer to Sheet 1 of the Schematic diagram 839-6208-088.
L.3.1.1 +5 VOLT SUPPLY
The modulation encoder board operates from +5 volts, from DC
L.2 Principles of Operation Regulator A30, and from a “Modulated B-” voltage, also from
DC regulator A30. (Refer to Section M, “DC Regulator,” for a
L.2.1 Modulation Encoding: Explanation and Exam-
description of the Modulated B- voltage, including its function.)
ple
The +5 volt supply line is fused by 5 ampere fuse F1, and
The digital audio signal consists of a stream of 12-bit digital
capacitors C1 through C3 provide additional filtering. Transzorb
“words.” The 12 bits are referred to as B1 through B12, where
CR2 provides transient protection. Test point TP2 allows check-
B1 is the MSB (Most Significant Bit) and B12 is the LSB (Least
ing the +5 volts on the Modulation Encoder board. All integrated
Significant Bit). Each word can be written in binary form, with
circuits on the board operate from the +5 volt supply.
the MSB first and the LSB last, for example, “011010 001101.”
Each of the LAST six bits (“001101" in this example) turns a L.3.1.2 Modulated B-
Binary Module on or off. In this case, the 1/2 step and 1/4 step The Modulated B- voltage is also fused, with F2, and transzorb
are OFF, and the 1/8 and 1/16 steps are ON. Bit 11 (1/32 step) CR3 provides transient protection. Test point TP1 allows moni-
is OFF, and Bit 12 (1/64 step) is ON. toring the modulated B-voltage. All modulation encoder board
PA module on/off signal outputs connect to the Modulated B-
The first six bits (“011010" in this example) control 42 “Big
line through a resistor.
Step” PA modules, the six binary bits must be encoded first. For
the first “Big Step,” only one PA module is turned on; for the L.3.2 Circuit Descriptions: Digital Audio Data Cir-
second “Big Step,” the first module remains ON and a second cuits
module also turns on, and so on. (If you convert the first six
binary bits to a decimal number, you can determine the number L.3.3 Data Input Latches (U49, U50)
of PA modules that are “on”; in the example, Binary 011010 The 12-bit digital audio inputs from the A/D board are at J17
equals decimal 26, so that the first 26 “Big Step” modules are pins 2 through 24 (odd numbered pins are Ground). Resistive
“ON.” dividers, sections of R10 and R11, parallel dividers at the A/D
The six most significant bits can provide up to 63 steps. In the board outputs. The digital audio inputs then go to inputs of Data
DX-10, however, only 42 “Big Steps” are used. An example may Latches U49 and U50.
help: L.3.3.1 “Binary Step” Digital Audio Circuits (U31, U60-
U61, U1, U2, U62)
L.2.2 Modulation Encoding: Read Only Memories The six LSB’s (Least Significant Bits, Bits 7 through 12) are
“Encoding” uses 256 word by 8 bit ROM’s (Read Only Memo- inputs to Latch U31. Each output of U31 goes to an OR gate, and
ries). The eight MSB’s (Most Significant Bits) of the encoded is OR’ed with a “CLIP” signal (discussed in a following para-
audio are the eight data inputs of each ROM (at pins 1-5 and graph). The six OR gate outputs go through terminals (E1
17-19), and can address any of 256 memory locations in the through E12), which are all jumpered in the DX-10. (In higher
ROM. During factory programming of the ROM’s, an 8-bit power DX-series transmitters, the jumpers at E9-E10 and/or
digital word is stored at each memory location. E11-E12 will be removed.)
When a memory location is addressed, the 8-bit digital word From the “jumpers,” each of the six LSB’s goes to a section of
stored at that location appears at the outputs of the IC (pins 6-9 DIP switch S1. S1 allows turning off individual binary modules
and 11-14). Each bit of the digital word provides a turn-on/turn- for troubleshooting or for emergency operation. The side of each
off signal for a PA module. switch nearest the “Binary Step” PA modules goes to an in-
ing these “glitches” by proper adjustment of modulated B- will outputs go to zero, turning off all PA modules; therefore, the
minimize spurious signal outputs from the transmitter. DATA CLEAR signal is also called a PA TURN-OFF signal.
Adjustment of Modulated B- is frequency dependent, and is The PA Turn Off (or Data Clear) input is at J17 pin 28. (Again,
described in the Tuning/Frequency Change procedure in Section refer to Sheet 1 of the Modulation Encoder schematic diagram.)
5, Maintenance, in this technical manual. Buffer/driver U59B drives the CLEAR inputs of all latches on
L.3.6 Data Strobe Signal Circuit: Data Latch the Modulation Encoder board. Test point TP4 provides a con-
venient point for observing the Data Clear pulse. (Buffer/driver
“Clock” Inputs
U59B has an open-collector output, which is paralleled with
A DATA STROBE logic signal from the A/D (Analog to Digital)
other open-collector buffer/driver outputs, shown on sheet 4 of
Converter board “strobes” or “clocks” the latches. The DATA
the schematic diagram; PA Turn-Off circuits are described fur-
STROBE input is at J17 pin 26 (refer to Sheet 1 of the Modula-
ther, later in this section).
tion Encoder Schematic diagram). Resistors R11 (pins 10 to 6)
and R11 (pins 6 to 1) form a voltage divider, or pull-up and L.3.8 “Clip” Function (“Clip-H” and “Clip-L” Sig-
pull-down resistor at the input; these parallel a similar divider at nals)
the output of the A/D Converter board. This DATA STROBE “Clip” Function: Description. When ALL “Binary Step” and
line is pulled to ground by the inverter/driver on the A/D board “Big Step” modules are turned on, and the Digital Audio signal
when the Data Strobe-L (TTL logic LOW) pulse is present. increases still more (which would require yet another module to
Each latch is CLOCKED by a low-to-high transition, so the turn on) the logic “HIGH” turn-on signal for that module is
DATA STROBE pulse must be inverted. Inverter/driver U57F returned through a “patch cord,” P15, to the “Binary Step”
provides the low-to-high transition at the beginning of the Data circuits and holds them all ON (see sheets 1 and 3 of the
Strobe pulse to drive all latches on the Modulation Encoder schematic).
board. Test point TP3 allows observing the Data Strobe pulses. L.3.8.1 “Clip” Function: What Happens if the Clip-L Patch
Each latch is an Octal D-type flip-flop. The “low-to-high” (P15) is not Connected?
TRANSITION at the leading edge of each Data Strobe pulse As the analog input signal to the A/D converter increases, the
from U57F causes each latch flip-flop’s output to change to the A/D output consists of larger digital audio “words.” When a “Big
same logic state as its input. All latch outputs will then remain Step” turns on, all “Binary Steps” turn off, then as the digital
in that logic state until the next Data Strobe pulse (or until a audio words continue to become larger the “Binary Steps” begin
DATA CLEAR, logic LOW signal, appears at the latch CLEAR turning on in a binary sequence to increase the transmitter’s rf
inputs). output in small increments. When ALL “Binary Steps” are ON,
the next “Big Step” turns on and all “Binary Steps” turn off again.
On the Schematic Diagram, note that the Data Strobe line also
goes to sheets 2 and 3. When ALL “Big Steps” are on and all “Binary Steps” are on, the
next larger digital audio “word” provides a turn-on signal for a
L.3.7 PA Turn-Off (“Data Clear”) Input “Big Step” that does not exist. All “Binary Steps” turn off,
Each digital data Latch (see the paragraph above) also has a however, so that the transmitter’s rf output suddenly drops by
CLEAR input. When the CLEAR input is logic LOW, all latch
On the modulation encoder board, LED indicators DS1 (red) and c. “PA Turn-Off” signal, from fault and overload circuits on
DS2 (green) provide a RED indication if an interlock fault LED Board A32.
(“error”) exists, or GREEN if all interlock chains are complete. “HIGH SPEED” Inputs:
L.3.12.1 “INTLK OFF” (“ERROR”) Indication a. “PA Turn Off” signal from Output Monitor A27 (when a
These indicators are driven by buffer/driver U59F. When there VSWR occurs).
is an “Interlock Error,” the input and output of U59F are LOW, b. “Data Clear” signal from A/D Converter Board A24 (also
and current flow through R170 and DS1 illuminates red LED called “PA Turn-Off”).
DS1. Diode CR4 also conducts through R171, pulling the junc-
tion of R171-CR4-CR5 LOW so that no current flows through L.3.13.1 Circuit Description
green LED, DS2. Diode CR5 ensures that DS2 will not conduct Refer to Sheet 4 of the Modulation Encoder Schematic Diagram
even if U59’s output is not pulled down to zero volts. for the following discussion. Figure L-3 and L-4 are simplified
diagrams of PA turn-off logic.
L.3.12.2 “INTLK ON” Indication
When there is no “Interlock Error,” the input and output of U59F PA Turn-off Logic effectively consists of “OR” gates, so that
are both HIGH. DS1 and CR4 do not conduct, and current flows any of the input signals listed above will produce the logic LOW
through R171, CR5, and DS2. “PA Turn-Off” signal to the CLEAR inputs of all Data Latches
on the Modulation Encoder board. L-87. Gate U56C’s output
L.3.13 “PA Turn Off” Logic (pin 8) goes LOW if one or more inputs goes LOW. That is, the
PA Turn Off logic generates a logic LOW “DATA CLEAR” (PA gate’s output goes LOW if the “Cable Interlock Fault” at pin 11
Turn-Off) signal which CLEARS all data latches on the Modu- goes LOW OR “power-up reset” at pin 10 goes LOW OR “PA
lation Encoder board, so that their outputs all go LOW. The Turn Off” from the LED board goes LOW.
LOW outputs turn off all PA modules. Three open-collector buffer/drivers make up a second OR gate,
Inputs to PA Turn Off logic on the Modulation Encoder board as shown in Figure L-4. Inputs are the Data Clear from the A/D
include: converter (to U59B, shown on Sheet 1 of the schematic); the PA
a. “Cable Interlock Error,” from a circuit on the Modulation Turn-Off from VSWR detectors on the Output Monitor board
Encoder board. (to U59A), and the output of “OR” gate U56C (to U59D).
b. “Power-Up Reset,” from a circuit on the Modulation En- If one or more of these inputs go LOW, the “PA Turn Off” line
coder board. to latch “CLEAR” inputs goes LOW. Because there are fewer
Figure L-4
Parallel Open-Collector outputs as an “OR” function
(If U59A OR U59D).
L.5.5 Symptom:
Red “INTLK OFF” Indication on the Modulation Encoder Board
Figure M-1
Block diagram, UC3834 Linear Regulator.
Figure M-2
Basic positive and negative voltage regulator circuits.
Figure M-3
Simplified diagram, 24VAC source for AC contactors. Note that the 24 volt AC
circuit is isolated from ground and one side of the 24VAC circuit is at +30VDC.
Figure M-4
Contactor Drive, Interlock and Interlock Status circuits simplified diagram.
Figure N-1
External Interface, typical status output circuits.
Figure N-3
Equivalent circuits for calculation effect of circuit loading
on Monitor voltage outputs.
Possible Causes:
N.4.3.1 No Supply Voltage For Status Circuits
N.3 Maintenance A positive voltage through circuits external to the transmitter
Refer to Section 5, Maintenance, for information on maintaining must be supplied to each status output used, at the proper
printed circuit boards. No other preventive maintenance is re- terminal on TB1 or TB2. For each remote Status output, when
quired on the External Interface board. there is no red status indication on the transmitter status panel or
illuminated pushbutton switch, there should be a positive voltage
on the corresponding terminal on TB1 or TB2. The diode from
the status output transistor collector to +22 volts is only for
N.4 Troubleshooting protection, and is not a supply voltage. Determine where the
supply voltage for external status circuits comes from, then
N.4.1 Symptom: No Remote Control Inputs Operate check that supply.
In this section, circuit operation is discussed; the turn-on/turn-off Although the turn-on/turn-off control logic is straightforward
control logic sequence is also described. Section 4, “System and fairly simple, you will probably have to work through the
Theory,” also includes a shorter description, emphasizing func- following explanation several times to understand the circuit.
tion and logic flow rather then circuit descriptions. Most transmitter turn-on/turn-off circuits require some study to
understand, because often one step must be completed before the
The Controller board is located on the back side of the transmit- next can be started, and because fault and overload inputs can
ter’s center front door. The Controller board is the lower board; modify or stop the turn-on sequence.
the LED board is located above it.
P.3.0.1 Basic Turn-On Sequence Requirements
The DX-10 has no filaments to warm up, so a “Turn On Request”
immediately starts the high voltage supply step-start sequence.
Primary power is initially applied to the high voltage power
P.2 Principles of Operation supply through surge limiting resistors, in the first step of the
This section describes circuits on the Controller printed circuit step-start sequence. The RF power amplifiers are held off during
board. The description will be divided into functional groups of this time, so that the PA does not load the power supply as its
circuits, as follows: filter capacitors charge (the RF Driver section does load the
a. Turn-on/Turn-off Control Logic. supply lightly). Also, the first step-start relay is checked; if it has
b. Power Control Logic. closed, the turn-on sequence continues.
c. “Interlock Status” Fault Logic. After a short time delay, rf drive level is checked (for both
d. +5B Reset Circuit. overdrive and underdrive; either could damage to PA modules
e. Power Supplies (+5, +15, -15 volt regulators). when they are turned on). If drive is not correct, the transmitter
is turned off immediately. There are two possible causes of low
f. Supply Fault Logic.
rf drive. First, an rf drive section fault can result in no drive or
g. Analog Monitor Buffer/Drivers, for Metering. low drive, and second, a high voltage supply fault can result in
Circuit descriptions refer to the Controller board Schematic low supply voltage to the rf driver, and therefore low rf drive
Diagram (839-6208-100, sheets 1, 2 and 3), as well as to block level.
diagrams and simplified schematic diagrams in this section.
If rf drive level is correct, and the second step-start relay (K2)
closes to apply primary power directly to the high voltage supply
transformer, power control circuits become completely opera-
tional and after an additional short time delay the “PA Off” logic
P.3 Transmitter Turn-On/Turn-Off Con- signal is released so that the transmitter begins operating at the
trol Logic selected power level (High, Medium or Low power).
The transmitter turn-on/turn-off control logic, located on the
Controller Board, provides drive signals for step-start relays K1 P.3.1 Inputs to Turn-On/Turn-Off Control Logic
and K2, and also provides logic signals to inhibit various trans- Logic signals, the circuit which generates them, and their basic
mitter functions, during the step-start sequence and when the function are:
transmitter is off. a. TURN-ON REQUEST, from Power Control Logic:
A “Turn-on Request” from the power control logic starts the 1. Starts turn-on sequence.
turn-on sequence. Turn-on/turn-off control logic turns the trans- b. “OFF” (Logic HIGH), from Power Control Logic:
mitter on in stages or steps, and provides logic outputs to other 1. De-energizes step-start contactor K2, and
parts of the transmitter during the turn-on sequence. If something
2. Generates “PA Off” logic signal, and
goes wrong during the turn-on sequence, turn-on may either be
3. Sets Power Control latch (U42) to “OFF.”
Figure P-2
Power Control logic simplified block diagram.
down resistor holds the transistor’s base at ground and the a. VSWR INDUCED LOWER COMMAND. A Logic
transistor is OFF. When the pushbutton switch is depressed, the HIGH input from the VSWR Fault circuits on LED Board
transistor’s input circuit goes to +15 volts through the pushbutton A32 turns on Q4C.
switch, the transistor turns ON, and the transistor collector goes b. “TYPE 1 FAULT” INDUCED “OFF” COMMAND.
LOW. Either a Type 1 Fault, logic HIGH signal from the LED
P.7.1.2 “Extended Control” Inputs board or an Interlock Fault from the Controller board
Each extended control input comes from an opto-isolator on the causes the output of OR gate U56C to go HIGH, turning
External Interface Board, A28. When sufficient current flows on transistor Q4A.
through the opto-isolator’s input LED, its transistor turns ON,
P.7.2 Inhibit Gates (U46A, U46B, U46C)
again pulling the collector line to ground (unless the “Local-Re-
mote” switch is in the “Local” position). The opto-isolator’s In the DX-10, these three gates act as buffers. The output of each
internal transistor is paralleled with the corresponding Local gate is normally HIGH and goes LOW when its control input is
Control input transistor, so that when it turns on it also pulls to active (Control inputs are U46C-9, U46B-5, and U46A-2). The
ground the input to switch de-bounce IC or to an OR gate (U46A, “Inhibit” inputs (U46C-10, U46B-4, and U46A-1) remain in a
U46B or U46C) LOW. logic LOW state. Recall that an OR gate output is LOW if both
inputs are LOW, and is HIGH if one or both inputs are HIGH.
The opto-isolator’s transistor emitters are connected together, at
the controller input, and go to a “Local-Remote” switch, which A logic HIGH at the gate’s Inhibit Inputs (pins 10, 4, and 1)
is mounted on the LED board and is a front-panel control (a would hold the OR gate outputs HIGH and block “High,”
toggle switch, on the Status Panel). When the switch is in the “Medium,” or “Raise” control inputs by preventing the gate
“Local” position, the emitters are returned to +5 volts, so that the outputs and Switch Debounce IC inputs from going LOW. The
“Remote” inputs at External Interface terminal boards TB1 and “Combiner Crowbar Fault” input is not used in the DX-10, so
TB2 cannot operate. When the switch is in the “Remote” posi- U51C’s input is always HIGH and its output is LOW. Transistor
tion, the opto-isolator emitters are all grounded and the “Re- Q4 also remains OFF.
mote” inputs can operate (all “Local” inputs still operate as well; P.7.3 Switch De-Bounce (U37)
they are not affected by the “Local-Remote” switch position).
The Switch De-Bounce uses an MC14490 integrated circuit
P.7.1.3 “Fault-Induced” Commands, Command Inputs “Hex Contact Bounce Eliminator,” which includes six inde-
From Fault and Overload Circuits pendent “contact bounce eliminator” sections and an internal
Three transmitter “Fault” conditions provide power level “Com- “clock” oscillator. Each contact bounce eliminator’s input is
mand” inputs. Each “Fault” condition turns on a transistor which pulled “HIGH” by an internal pull-up resistor to the +5 volt
is paralleled with the Local Control input and Extended Control supply, unless a command pulls the input LOW to activate the
input transistors, so that a “Fault” induced command will also input. (More usual contact bounce eliminator circuits require a
pull the corresponding switch de-bounce IC input LOW. Fault- switch with two sections, one normally open and one normally
induced commands include:
Figure P-7
Multiplex and Latch simplified diagram.
P.8.1.2 Door Interlock Circuit If the +30 volts fails, or if one or both relays de-energize (opening
When both doors are closed, the door interlock switches ground one or both contacts) the Controller board Interlock String input
the “Door Interlock” input to the Interlock Status logic on the is pulled to ground (Logic LOW) through R121 (on the Control-
Controller board. If one or both doors are open, +30 volts is ler board).
applied to the “Door Interlock” input on the Controller board,
through a resistance on the DC Regulator board (A30).
P.8.1.3 Door Interlock Relay K4
Additional sections on both door interlock switches also ener-
gize an ac relay, K4, when the doors are closed. If either or both
doors are open, K4 de-energizes. The “Interlock String” circuit
through this relay contact protects against loss of the +30 volt
supply for the interlock “fault” inputs.
P.8.1.4 External Interlock Input
External interlocks may include interlocks on enclosures with rf
power inside, such as phasor cabinets; air or water flow inter-
locks on dummy loads; interlocks on rf power contactors to
prevent applying rf power if contactors do not operate properly;
and any other external interlocks which may be required by your
system. When external interlocks are properly used, the External
Interlock circuit protects personnel from contact with hazardous Figure P-8
rf voltages, and protects the transmitter, rf switching equipment, 24 Volt AC supply for External Interlock
simplified diagram.
The following description is rather detailed. If you are familiar HIGH ON LOW —OFF HIGH
with logic circuits, you may want to simply refer to the simplified LOW OFF HIGH —ON LOW (Fault)
diagram, Figure P-9, which includes logic levels for “Fault” P.8.4.4.1 No Interlock String Fault: (Circuit Operation)
conditions. The Interlock Status input is normally a logic “HIGH” input,
because when both interlock relays (K3 and K4) are energized
We will look at the input circuits one part at a time; for parts of
Q12C’s base circuit goes to the +30 volt supply through their
the input circuit description, other components will be ignored,
contacts. Base current flows through R117, and Q12C is turned
and an “on” or “off” condition may be assumed.
ON. Resistor R121 has almost no effect, because the base is held
P.8.4.1 “Door Interlock” and “External Interlock” Status at about 0.6 volts, Q12C’s base-emitter junction drop. Q12C’s
Circuit Inputs collector is LOW (pulled to almost zero volts), so that Q12D’s
For now, assume that Q12D is OFF (open collector) and can be base resistor returns essentially to ground and no base current
ignored. Recall that an Interlock Fault status indication and Fault flows. Q12D is OFF, and its collector is HIGH, providing a “No
logic output are generated when the delay input circuit is logic Fault” input to the delay timer.
LOW. For a Door Interlock fault, Q12A must conduct (turn ON),
P.8.4.4.2 “Interlock String” Fault: (Circuit operation)
and its input must be “HIGH.” For an External Interlock fault,
Q13 must turn ON (input “HIGH”). These conditions are listed Any interlock string failure, including loss of +30 volts, removes
below for reference: the +30 volts to R117. Q12C’s base goes to ground through
pull-down resistor R121 and the input is therefore “Low.” Q12C
a. Door Interlock Status: is turned OFF, and its collector goes HIGH (open circuit).
NORMAL: Input LOW, Q12A OFF (collector HIGH). Q12C’s open collector goes to almost +5 volts (at the junction
FAULT: Input HIGH, Q12A ON (collector LOW). of a voltage divider, R124 and R123). (Again, assume for now
b. External Interlock Status: that Q12B is also OFF so that its collector is also an “open
NORMAL: Input LOW, Q13 OFF (collector HIGH). circuit”). Q12D’s input is HIGH, and Q12D turns ON. Q12D
FAULT: Input HIGH, Q13 ON (collector LOW). collector goes LOW, starting the delay time, and after about 0.15
P.8.4.2 “Door Interlock” Inputs seconds a Door Interlock Fault output is generated.
Refer to Figure P-9, Interlock Status Logic, Simplified Diagram, P.8.4.5 Transistor “Logic Circuits”
or to sheet 1 of the Controller schematic diagram. The Door Q12A and Q12D function as a NOR gate. They have separate
Interlock input transistor is Q12A (assume for now that Q12D is inputs, but their collectors are tied together. If either transistor
OFF and will not affect operation of this input circuit). The base conducts (or both transistors conduct) their common collector
circuit input for Q12A is GROUNDED through the interlock line will be pulled LOW. The collector line will go high only
switches if the doors are closed, the transistor is turned off, and when both transistors are OFF. The common collector line is the
its collector is high. gate’s output.
When one or both doors opens (“Interlock FAULT” condition), When an NPN transistor’s base is “LOW,” it is turned OFF;
the ground is removed, and the input goes “High.” Transistor when its base is “HIGH,” it is turned ON. For this circuit, then,
base current flows from the +30 volt supply through series if Q12A’s input is HIGH, “OR” if Q12D’s input is HIGH, (or
current limiting resistors. The transistor turns ON and its collec- both inputs are HIGH), the output is LOW. If both inputs are
tor goes LOW, and after a delay of about 0.15 seconds the circuit LOW, the output is HIGH.
provides a “Door Interlock Fault-L” output. For this circuit, then, a “Door Interlock Fault” (Q12A input
P.8.4.3 “External Interlock” Input HIGH), OR an “Interlock String Fault” (Q12D input HIGH), or
The External Interlock transistor is Q13. When the external both, the circuit’s output (Q12A-Q12D collector) is “Fault-
interlock circuit is closed, 24 volt ac relay K3 is energized, and LOW” and a “Door Interlock Fault-L” is generated at the status
a relay contact grounds the input to the Controller board. When logic output.
the external interlock circuit opens, K3’s contact opens, the input
P.8.5 “Interlock Fault” Logic Output (for any Inter- P.10 Power Supplies (+5V, +15V and -15
lock Fault)
The “Door Interlock Fault” (Fault LOW) output from U73B and
V Regulators
On-board regulators supply +5 volts for all logic circuits on the
the “External Interlock Fault” (Fault LOW) output from U73A
Controller board, and also supply +15 V and -15 V for the analog
are inverted by U73C and U73D (two-input gates with the inputs
monitor/ metering buffer/drivers. A “+5B” back-up supply,
tied together to use as inverters). The inverted, logic HIGH if
which supplies all critical memory circuits when the transmit-
fault signals go to OR gate U58D. A Door Interlock Fault or an
ter’s primary power fails or is turned off, is also located on the
External Interlock Fault (or both) will cause an “Interlock Fault”
Controller board.
logic HIGH output from U58D.
These supplies also provide operating voltages for LED Board
P.8.6 Type 1 Fault Gate, U58C A32, and the +5B supply provides a back-up supply voltage for
The “Interlock Fault” logic HIGH output is OR’ed with a “Type memory on the LED board as well.
1 Fault - H” signal from the LED Board (A32). Any Type 1 Fault,
Sheet 3 of the Controller schematic diagram shows the voltage
including Interlock Faults, turn the transmitter OFF. The output
regulator circuits and “Supply Fault” logic which are located on
of OR gate U58C goes HIGH when a Type 1 Fault occurs, and
this board.
turns Q4A “ON” to generate a Transmitter “OFF” command
input. P.10.1 DC Regulator Circuits
The “Type 1 Fault - H” output from U58C also goes to U53C to Refer to Section M, DC Regulator, in this Technical Manual for
generate an Inhibit K2 logic signal. U53C and the Inhibit K2 descriptions of the voltage regulator circuits using UC3834
signal are described in the “Turn-On/Turn-Off Control Logic” linear voltage regulator IC’s.
description in this section.
P.10.2 +5B (Backup) Supply
The +5B supply includes BT1, BT2 and BT3 (optional back-up
batteries), a one farad energy storage capacitor C94, diodes CR3
and CR4, and current limiting resistors R83 and R84. This circuit
P.9 +5B Reset Circuit (U66)
is shown on sheet 3 of the Controller schematic diagram, at
All circuits supplied from the +5B backup supply are specified
locations A6 and B6.
to operate reliably at supply voltages as low as +3 volts. If the
+5B supply voltage drops below this value, the +5B RESET P.10.2.1 Energy Storage Capacitor
circuit generates two RESET signals (+5B RESET-L, a logic The back-up supply uses a very large, low-voltage energy stor-
LOW signal and +5B RESET-H, a logic HIGH signal). These age capacitor with a one farad capacitance. Capacitors of this
signals reset all latches (“memory”) to zero. type are intended for use in low-current memory backup appli-
cations. The capacitor, C94, is initially charged from the +5 volt
The +5B Reset circuit is shown on sheet 1 of the Controller supply, through diode CR4 and resistor R83. When primary
schematic diagram, in the upper right corner. The circuit uses power is present, the +5 volt supply also maintains charge on the
two sections of an LP339 low-power comparator. capacitor.
Comparator U66A has two inputs. The inverting input, at pin 6, If the +5 volt supply fails, either because of loss of transmitter
is a +1.22 volt reference voltage from zener diode CR12. The ac primary power or a supply fault, diode CR4 will be reverse-
non-inverting input, at pin 7, is a sample of the +5B voltage from biased so that capacitor C94 discharges only into the circuits on
voltage divider R48-R49. Feedback resistor R47 introduces the Controller and LED boards. Total current drain from the
some hysteresis, so that the “Fault” outputs occur when the +5B back-up supply, when the +5 volt supply fails, is less than 1
supply drops below about +3.1 volts and clear again when the milliampere, so that the capacitor alone can maintain memory
+5B supply increases above about +4.2 volts. for two hours or more.
Figure P-10
Controller board “Supply Fault”
regulator fault circuit simplified diagram.
P.12.4 Adjustments
There are no adjustments on the Controller board.
P.12 Maintenance
P.12.1 Printed Circuit Board Maintenance
General printed circuit board maintenance procedures are de-
scribed in Section 5, “Maintenance,” in this technical manual.
Figure Q-3
Latched Fault status indicators simplified diagram.
e. Status indicator “Inhibit” gates which turn off all front- When a FAULT is latched, U15A’s Q output is HIGH and is
panel status indications for a short time after initial turn-on inverted by U17D to a LOW and again by inverter U18D to a
(U17B, 17D). HIGH, which illuminates the RED section of indicator DS5.
Q.7.3.1 “Anti Flutter” Delay, U12A Similarly, the LOW not-Q output causes the green section of
When air pressure switch S7 first closes, +8 volts is supplied to DS5 to be dark. Also, the LOW not-Q output is inverted by U18C
an RC charge-discharge circuit (R213, R63 and C119). The to provide an AIR FAULT - H logic signal to the external
capacitor begins charging through the series resistance, and after interface (refer to the schematic diagram). When there is NO
about 0.6 seconds inverting Schmitt trigger U12A’s output goes fault latched, U18D’s Q output is LOW and the RED LED
LOW, indicating normal air flow (no fault). If an Air Flow Fault section is OFF, and U18D’s not-Q output is HIGH and the
occurs, pressure switch S7 will OPEN and C119 will begin GREEN LED section is illuminated.
discharging through a resistance to ground. After about 1 second, Q.7.3.2.1 Inhibit “Air Interlock” Status Indication (Gates U17D
inverting Schmitt trigger U12A’s output goes HIGH, indicating and U17B)
an air flow FAULT. If the air switch opens for a short time When the transmitter is first turned ON and the Overdrive Inhibit
because of air flow “flutter”, the charge-discharge circuit holds is released, the “Inhibit” logic in the Air Flow circuit generates
U12A’s output LOW (“no-fault”). a 3.5 second logic LOW pulse which goes to U17D-pin 12 and
U17B-pin 10. This logic LOW pulse holds both NAND outputs
The output of the delay circuit, from U12A is FAULT - HIGH
HIGH, preventing any status indication (either green or red).
and Normal - LOW. This is one input to AND gate U13B (at pin
4); U13B’s other input (pin 5) is an “Inhibit - L” input which is Q.7.3.2.2 Inhibit Logic
LOW if the PA is OFF and also for 3.5 seconds after PA turn-on. The inhibit logic prevents an air flow fault from being sensed for
3.5 seconds after transmitter turn-on, to allow air flow to be
The Inhibit-L at U13B pin 5 forces U13B’s output LOW even if
established, and also turns off the Air Interlock status indicator
a fault occurs. When the Inhibit is removed and pin 5 goes HIGH,
during this time. Air flow fault circuit “inhibit” logic includes
a normal air flow -logic LOW signal from U12A holds U13B’s
delay circuit U12C-U12B, gate U13A to provide an “Inhibit fault
output LOW, and an air flow FAULT - H causes U13B’s output
sensing” signal, inverter U12D, and gate U20A to provide an
to go HIGH. U13B’s FAULT-H output goes to Type 1 Fault gate
“Inhibit indication” signal. The Inhibit Logic has one input and
U10 and to the status indicator circuit.
two outputs:
Q.7.3.2 “Air Interlock” Status Indicator Circuit
The Status Indicator circuit consists of Reset Retrigger AND a. INPUT: “OVERDRIVE INHIBIT - L”, from the turn-
gate U14D, latch U15, inhibit gates U17D and U17B, indicator on/turn-off logic on the controller board. If the transmitter
drivers U18C and U18B, and AIR indicator LED DS5. Operation is OFF this input is logic LOW; a little over 1 second after
of the Reset Retrigger AND gate and Latch were described the beginning of the turn-on step-start cycle, when the PA
earlier in this section, in the paragraphs on the “Reset Circuit”. Turn-Off is released by the controller board turn-on/turn-
Figure Q-9
RF Sense circuits simplified diagram.